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Recreational Vehicle Chassis: Maintenance Manual

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Recreational Vehicle Chassis: Maintenance Manual

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RECREATIONAL VEHICLE

CHASSIS
Maintenance Manual
Part Number A24-00788-000
Publication Number STI-425-6
RECREATIONAL VEHICLE CHASSIS MAINTENANCE
MANUAL

Models: MC
MCL
XCL
XCM
XCP
XCR
XCS

STI-425-6 (7/18)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
Foreword
Scheduled maintenance provides a key element for safe operation of your vehicle. A proper maintenance
program also helps to minimize downtime and to safeguard warranties. This maintenance manual provides
information necessary for years of safe, reliable, and cost-efficient vehicle operation.
IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also refer to other
component and body manufacturers’ instructions for specific inspection and maintenance instruc-
tions.
Perform the pretrip inspection and daily/weekly/monthly maintenance as outlined in the vehicle operator’s
manual. Perform the operations in this maintenance manual at scheduled intervals based upon distance
traveled or months of operation. Your authorized servicing dealer has the qualified technicians and equipment
to perform this maintenance for you. Your dealership can also set up a scheduled maintenance program
tailored specifically to your needs. Optionally, your dealership can assist you in learning how to perform the
maintenance procedures in this manual.
IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing.
Freightliner Custom Chassis Corporation (FCCC) reserves the right to discontinue models and to
change specifications or design at any time without notice and without incurring obligation.
Descriptions and specifications contained in this publication provide no warranty, expressed or
implied, and are subject to revision and editions without notice.
Refer to www.Daimler-TrucksNorthAmerica.com and www.FreightlinerChassis.com for more informa-
tion, or contact Daimler Trucks North America LLC at the address below.

Environmental Concerns and Recommendations

Whenever you see instructions in this manual to discard materials, you should attempt to reclaim and recycle
them. To preserve our environment, follow appropriate environmental rules and regulations when disposing of
materials.

NOTICE: Parts Replacement Considerations

Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears) with
used parts. Used parts may have been subjected to collisions or improper use and have undetected structural
damage.

© 1997–2018 Daimler Trucks North America LLC

All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a
retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or
otherwise, without the prior written permission of Daimler Trucks North America LLC. Daimler Trucks North
America is a Daimler company.

Daimler Trucks North America LLC

Service Systems and Documentation (CVI-SSD)
P.O. Box 3849
Portland, OR 97208-3849
Introduction
Descriptions of Service Publications

Daimler Trucks North America LLC distributes the following major service publications in paper and electronic
formats. Refer to www.DTNAConnect.com.
Workshop/Service Workshop/service manuals contain service and repair information for all vehicle
Manual systems and components, except for major components such as engines, trans-
missions, and rear axles. Each workshop/service manual section is divided into
subjects that can include general information, principles of operation, removal,
disassembly, assembly, installation, and specifications.
Maintenance Manual Maintenance manuals contain routine maintenance procedures and intervals for
vehicle components and systems. They have information such as lubrication
procedures and tables, fluid replacement procedures, fluid capacities, specifica-
tions, and procedures for adjustments and for checking the tightness of fasten-
ers. Maintenance manuals do not contain detailed repair or service information.
Driver’s/Operator’s Driver’s/operator’s manuals contain information needed to enhance the driver’s
Manual understanding of how to operate and care for the vehicle and its components.
Each manual contains a chapter that covers pre-trip and post-trip inspections,
and daily, weekly, and monthly maintenance of vehicle components.
Driver’s/operator’s manuals do not contain detailed repair or service information.
Service Bulletins Service bulletins provide the latest service tips, field repairs, product improve-
ments, and related information. Some service bulletins are updates to informa-
tion in the workshop/service manual. These bulletins take precedence over
workshop/service manual information, until the latter is updated; at that time, the
bulletin is usually canceled. The service bulletins manual is available only to
dealers. When doing service work on a vehicle system or part, check for a valid
service bulletin for the latest information on the subject.
IMPORTANT: Before using a particular service bulletin, check the current
service bulletin validity list to be sure the bulletin is valid.
Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain
lists of parts and BOMs needed to do replacement and upgrade procedures.

Web-based repair, service, and parts documentation can be accessed using the following applications on the
www.DTNAConnect.com website.
DTNAConnect DTNAConnect provides Web-based access to the most up-to-date versions of
the publications listed above. In addition, the Service Solutions feature provides
diagnostic assistance with Symptoms Search, by connecting to a large knowl-
edge base gathered from technicians and service personnel. Search results for
both documents and service solutions can be narrowed by initially entering ve-
hicle identification data.
PartsPro PartsPro® is an electronic parts catalog system, showing the specified vehicle’s
build record.
EZWiring EZWiring™ makes Freightliner Custom Chassis Corporation, Freightliner, Ster-
ling, Thomas Built Buses, and Western Star products’ wiring drawings and float-
ing pin lists available online for viewing and printing. EZWiring can also be ac-
cessed from within PartsPro.

Recreational Vehicle Chassis Maintenance Manual, July 2018 I–1

Introduction
Descriptions of Service Publications

Warranty-related service information available on the www.DTNAConnect.com website includes the following
documentation.
Recall Campaigns Recall campaigns cover situations that involve service work or replacement of
parts in connection with a recall notice. These campaigns pertain to matters of
vehicle safety. All recall campaigns are distributed to dealers; customers receive
notices that apply to their vehicles.
Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or
replacement of parts. All field service campaigns are distributed to dealers; cus-
tomers receive notices that apply to their vehicles.

I–2 Recreational Vehicle Chassis Maintenance Manual, July 2018

Introduction
Page Description

For an example of a maintenance manual page, see Fig. 1.

A B C

Air Intake 09

09−01 Air Cleaner Inspecting air intake piping, or a disconnected or damaged air
restriction indicator.
and Replacing
NOTE: Remove and visually inspect the air
cleaner element for obvious damage such as H20 VACUUM IN H20 VACUUM
25
holes, cuts, or dents. Remove loose debris,
20
such as leaves or pine needles, from the filter 15
housing. 10
7
Inspect the air cleaner and plumbing for holes or
tears at the recommended interval. If the air cleaner PUSH TO RESET
is damaged, replace it. See Group 09 of the Recre−
ational Vehicle Chassis Workshop Manual for re−
moval and installation procedures, or take the vehicle
to an authorized Freightliner dealer. A typical air
cleaner mounting is shown in Fig. 1.

05/22/97 f090176

Fig. 2, Air Restriction Indicator

Replace the air cleaner at the recommended interval,

or when filter restriction reaches 25 inH2 O. See the
Recreational Vehicle Chassis Operator’s Manual for
specific restriction values for your engine. See
Group 09 of the Recreational Vehicle Chassis Work−
shop Manual for removal and installation procedures,
or take the vehicle to an authorized Freightliner
dealer.

09−02 Charge Air Cooler

Inspecting and Cleaning
07/11/2007 f090451 Good airflow through the radiator and charge air
cooler core is essential for proper engine cooling.
Fig. 1, Air Cleaner Mounting The cores allow air passage, but form a barrier that
tends to collect insects and airborne debris.
Engine damage can occur if the air intake system is If the charge air cooler core fins are bent, use a
not properly maintained. Use the air intake restriction small pair of needle−nose pliers or a small screw−
indicator to check for air intake system damage or driver to straighten them. If the fins are clogged, use
leaks. See Fig. 2. Make sure the engine is off and compressed air or water directed from the fan side of
note the existing reading on the indicator. Reset the the radiator core to backflush any material restricting
indicator by pushing it down. See Fig. 2. Start the airflow.
engine and take a short test drive. Check the indica−
tor again and note the level of restriction on the indi− Ensure that the hoses are not chafing and that the
cator, verifying it is at the same level as seen earlier. system is closed with no air leaks.
A decrease from the previous level of restriction or a
very low air restriction indicator reading (0 to 4
inH2 O) could indicate an air intake system problem
such as a damaged air filter, loose or disconnected

Recreational Vehicle Chassis Maintenance Manual, January 2010 09/1

D E
02/19/2013 f020181
A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number
B. Group Title
C. Group Number
D. Release Date
E. Group Number/Page Number
Fig. 1, Example of a Maintenance Manual Page

Recreational Vehicle Chassis Maintenance Manual, July 2018 I–3

Introduction
Maintenance Manual Contents

Group No. Group Title

00 . . . . . . . . . . . . . . . . . . . . . . General Information
01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine
09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Intake
15 . . . . . . . . . . . . . . . . . . . Alternators and Starters
20 . . . . . . . . . . . . . . . . . . . Engine Cooling/Radiator
26 . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission
30 . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Control
32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension
33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle
35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle
40 . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires
41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driveline
42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes
46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering
47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel
49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust
54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical
83 . . . . . . . . . . . . . . . . . Heater and Air Conditioner

I–4 Recreational Vehicle Chassis Maintenance Manual, July 2018

General Information 00
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

15,000 Mile or 12 Month Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–04
30,000 Mile or 24 Month Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–05
45,000 Mile or 36 Month Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–06
60,000 Mile or 48 Month Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–07
6000 Mile or 6 Month Initial Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–03
General Maintenance Schedule Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–01
Noise Emission Controls Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–08
Vehicle Maintenance Schedule Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–02
Verification of Inspections Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–09

Recreational Vehicle Chassis Maintenance Manual, April 2018

General Information 00
General Maintenance Schedule Information: 00–01

General Maintenance Schedule If needed, service work can be scheduled for your
vehicle at the service center during your stay.
Information
Tear-Out Checklists
General Maintenance Schedule IMPORTANT: Additional copies of the checklists
Information should be made before giving this to a dealer,
as they may not be returned to you. The correct
Performing regular maintenance on your vehicle will number of checklists are included to cover the
help ensure that your vehicle delivers safe reliable warranty period, however, if you want copies of
service and optimum performance for years to come.
the checklists for future maintenance after the
Failure to follow a regular maintenance program can
result in inefficient operation and unscheduled down warranty expires, you will need to make them.
time. Freightliner Custom Chassis Corporation
(FCCC) will not be able to send you additional
When the vehicle reaches the distance or time copies.
(whichever comes first) given for a maintenance in-
terval, see the Vehicle Maintenance Schedule Table At the back of the maintenance manual, there are
for a list of the maintenance operations to be per- checklists for each maintenance interval up to 60,000
formed at that maintenance interval. Use the mainte- miles (96 540 km). When a maintenance interval
nance operation reference numbers to find detailed needs to be performed, take the vehicle to an autho-
instructions in the manual for each operation. rized Freightliner dealer, remove the appropriate
checklist, and give it to the dealer. These are the
NOTE: Maintenance instructions in this manual items that will be inspected for maintenance.
are based on average vehicle use and normal
operating conditions. Unusual vehicle operating
conditions may require service at more frequent
intervals.
For specific engine maintenance information, see the
Cummins Operation and Maintenance Manual.
IMPORTANT: Maintenance operations appearing
in italics in the following tables are for emission
control components. Numbers in the table are
reference numbers matching those in the text of
this manual.

Camp Freightliner Owner

Training
Owners who want to learn more about their vehicle
can attend a two-day training class, offered at the
Freightliner Custom Chassis Service Center in Gaff-
ney, South Carolina. Some of the items covered dur-
ing the training include the air brake system, electri-
cal system, vehicle storage, weight distribution, and
maintenance intervals.
To learn more about the class or to register, go to
www.freightlinerchassis.com. After entering the
website, click "Motorhomes" and select "Owner Info".
A class description and the registration form are lo-
cated under the "Camp Freightliner" tab.

Recreational Vehicle Chassis Maintenance Manual, April 2018 00/1

00 General Information
Vehicle Maintenance Schedule Table: 00–02

Maintenance Operation Procedures and Schedule

Maintenance Interval in Miles x 1000
6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285
Maintenance Operation Number Maintenance Interval in Kilometers x 1000
and Description 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458
Maintenance Interval in Months
6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228
01–01 Engine Drive Belt Inspecting • • • • • • • • • • • • • • • • • • • •
01–02 Engine-Support Fasteners
• • • • • • • • • • • • • • • • • • • •
Checking
When first purchased, if the Recreational Vehicle is older than the current model year,
replace the air filter.
09–01 Air Cleaner Inspection and
Inspect the air cleaner every 12 months. Replace the air filter every 24 months, or
Replacement
when filter restriction exceeds the value shown in 09–01 (if equipped with an air
restriction gauge).
09–02 Charge Air Cooler (CAC)
• • • • • • • • • • • • • • • • • • • •
Inspection and Cleaning
13–01 Air Compressor Inspection • • • • • • • • • • • • • • • • • • •
15–01 Alternator, Battery, and
• • • • • • • • • • • • • • • • • • • •
Starter Connections Check
20–01 Radiator Cap Check • • • • • • • • • • • • • • • • • • • •
20–02 Radiator Inspection and
• • • • • • • • • • • • • • • • • • • •
Cleaning
Replace the organic acid technology (OAT) coolant every 600,000 miles (965 400
20–03 Coolant Replacement km). Supplemental coolant additives (SCAs) are not used with OAT coolant. See the
applicable engine operation and maintenance manual for further information.
20–04 Mechanical Fan Drive
• • • • • • • • • •
Gearbox Oil Change
20–05 Mechanical Fan Drive
• • • • • • • • • • • • • • • • • • •
Gearbox Lubrication
26–01 Transmission Breather
• • • • • • • • • • • • • • • • • • •
Checking
26–02 Allison MD/MH Series
• • • • • • • • • • • • • • • • • • • •
Transmission Fluid Level Checking
26–03 Allison Transmission Fluid
and Filter Changing (internal/ For oil and filter change intervals, see the applicable Allison Operator’s Manual.
external filter)
30–01 Throttle Pedal Pivot Pin
• • • • • • • • • • • • • • • • • • • •
Lubricating
32–01 Suspension Fastener
• • • • • • • • • •
Torque Check
32–02 Suspension Height Control
• • • • • • • • • • • • • • • • • • • •
Valve Check
32–03 Neway Suspension
• • • • • • • • • • • • • • • • • • • •
Inspection

00/2 Recreational Vehicle Chassis Maintenance Manual, April 2018

General Information 00
Vehicle Maintenance Schedule Table: 00–02

Maintenance Operation Procedures and Schedule

Maintenance Interval in Miles x 1000
6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285
Maintenance Operation Number Maintenance Interval in Kilometers x 1000
and Description 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458
Maintenance Interval in Months
6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228
32–04 ZF IFS Lubrication • • • • • • • • • • • • • • • • • • • •
32–05 Suspension Inspection • • • • • • • • • • • • • • • • • • • •
32–06 Suspension U-Bolt Torque
• • • • • • • • • • • • • • • • • • • •
Check
32–07 V-Ride Rear Suspension
• • • • • • • • • • • • • • • • • • • •
Inspection
33–01 Knuckle Pin Lubricating* • • • • • • • • • • • • • • • • • • • •
33–02 Tie-Rod End Lubricating
• • • • • • • • • • • • • • • • • • • •
and Inspecting*
33–03 All-Axle Alignment Checking •
33–04 Wheel End Inspection • • • • • • • • • • •
33–05 Oil-Filled Hubs Oil Level
• • • • • • • • • • • • • • • • • • • •
Checking
33–06 Oil-Filled Hubs Oil Changing • • • • • • • • • •
35–01 Axle Lubricant Level
• • • • • • • • • • • • • • • • • • • •
Checking
For Detroit rear axles with petroleum-based oil, change the lubricant every 100,000
miles (160 900 km) or every 12 months, whichever comes first; if synthetic oil is used,
change the lubricant every 250,000 miles (402 250 km) or every 36 months,
35–02 Axle Lubricant Changing
whichever comes first. For Meritor rear axles with petroleum-based oil, change the
and Magnetic Plug Cleaning
lubricant at 100,000 miles (160 900 km) or at 12 months of service, whichever comes
first, and every 24 months thereafter; if synthetic oil is used, change the lubricant
every 250,000 miles (402 250 km) or every 36 months, whichever comes first.
35–03 Axle Breather Checking • • • • • • • • • • • • • • • • • • • •
35–04 Oil-Filled Hubs Oil Level
• • • • • • • • • • • • • • • • • • • •
Checking, Tag Axle
35–05 Oil-Filled Hubs Oil
• • • • • • • • • •
Changing, Tag Axle
40–01 Wheel Nut Checking • • • • • • • • • •
40–02 Wheel Cleaning and
Perform these steps each time the wheels and/or the vehicle is washed.
Polishing
41–01 Driveline Inspection and
• • • • • • • • • • • • • • • • • • • •
Lubrication
42–01 Brake System Valves
• • • • • • • • • • • • • • • • • • • •
Inspecting
42–02 Air Dryer Checking • • • • • • • • • • • • • • • • • • • •

Recreational Vehicle Chassis Maintenance Manual, April 2018 00/3

00 General Information
Vehicle Maintenance Schedule Table: 00–02

Maintenance Operation Procedures and Schedule

Maintenance Interval in Miles x 1000
6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285
Maintenance Operation Number Maintenance Interval in Kilometers x 1000
and Description 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458
Maintenance Interval in Months
6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228
42–03 Air Dryer Desiccant and
• • • • • •
Coalescent Filter Replacing
42–04 Camshaft Bracket Bushing
• • • • • • • • • • • • • • • • • • • •
Lubricating
42–05 Slack Adjuster Lubricating • • • • • • • • • • • • • • • • • • • •
42–06 Foot Brake Valve Actuator
• • • • • • • • • • • • • • • • • • • •
Lubricating
42–07 Bendix Hydro-Max® Brake
System Inspecting (front-engine • • • • • • • • • • • • • • • • • • • •
diesel chassis)
42–08 Brake Caliper Slide Pin
Lubricating, Bosch Brakes (front- Lubricate every 6 months OR every 18,000 miles (28 962 km), whichever comes first.
engine diesel chassis)
42–09 Brake Lines Checking,
• • • • • • • • • • • • • • • • • • • •
Hydraulic Disc or Air Brakes
42–10 Brake Lining Wear
Checking, Hydraulic Disc Brakes • • • • • • • • • • • • • • • • • • • •
(front-engine diesel chassis)
42–11 Brake Inspecting • • • • • • • • • • • • • • • • • • • •
42–12 Meritor Roller Pin
• • • • • • • • • • • • • • • • • • •
Lubricating
42–13 Versajust Slack Adjuster Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating
Inspection and Lubrication hours, whichever comes first.
42–14 Bendix Automatic Drain
The automatic drain valve should be inspected every 6 months or 1500 operating
Valve Operating and Leakage
hours, whichever comes first.
Tests
46–01 Drag Link Lubricating • • • • • • • • • • • • • • • • • • • •
46–02 Power Steering Reservoir
• • • • • • • • • • • • • • • • • • • •
Fluid Level Checking
46–03 Power Steering Fluid and
Replace the power steering fluid and filter every 500,000 miles (804 500 km).
Filter Changing
46–04 Steering Driveline
• • • • • • • • • • • • • • • • • • • •
Lubricating
46–05 Steering Gear Lubricating • • • • • • • • • • • • • • • • • • • •
47–01 Fuel Tank Mounts and Fuel
• • • • • • • • • •
Line Checking

00/4 Recreational Vehicle Chassis Maintenance Manual, April 2018

General Information 00
Vehicle Maintenance Schedule Table: 00–02

Maintenance Operation Procedures and Schedule

Table 1, Maintenance Operation Procedures and Schedule

Recreational Vehicle Chassis Maintenance Manual, April 2018 00/5

00 General Information
6000 Mile or 6 Month Initial Maintenance: 00–03

Procedure
Performed
6000 Mile (9654 km) or 6 Month Initial Maintenance* MOP
(check off or
initial)
Inspect _____ Engine Drive Belt Inspecting 01–01
Check _____ Engine-Support Fasteners Checking 01–02
Engine Oil and Filter (see the engine manufacturer’s
Change _____ —
manual)
Charge Air Cooler (CAC) Inspection and Cleaning (if
Inspect _____ 09–02
cleaning is needed)
Check _____ Alternator, Battery, and Starter Connections Check 15–01
20–01,
Inspect/ Radiator (radiator cap, coolant freeze points, hose routing
_____ 20–02,
Check for chaffing and leaks)
20–03
Change _____ Mechanical Fan Drive Gearbox Oil Change 20–04
Change _____ Transmission Fluid and Filter (if required by Allison) 26–03
Inspect _____ Transmission Hose Routing for Chaffing and Leaks —
Lubricate _____ Throttle Pedal Pivot Pin Lubricating 30–01
Check _____ Suspension Fastener Torque Check 32–01
Check _____ Suspension Height Control Valve Check 32–02
Lubricate _____ ZF IFS Lubrication 32–04
Check _____ Suspension U-Bolt Torque Check 32–06
Inspection_____ V-Ride Rear Suspension Inspection 32–07
Lubricate _____ Knuckle Pin Lubricating† 33–01
Lubricate _____ Tie-Rod End Lubricating and Inspecting† 33–02
Check _____ All-Axle Alignment Checking 33–03
Inspect _____ Wheel End Inspecting 33–04
33–05,
Check/ 33–06,
_____ Oil-Filled Hubs Oil Changing (front and tag axle)
Change 35–04,
35–05
Check _____ Axle Seals for Leaks —
Axle Lubricant Changing and Magnetic Plug Cleaning
Change _____ 35–02
(Detroit and Meritor axles)
Check _____ Axle Breather Checking 35–03
Check _____ Wheel Nut Checking 40–01
Check _____ Tire Pressure —
Lubricate _____ Driveline Inspection and Lubrication 41–01
Inspect _____ Brake System Valves Inspecting 42–01
Air Dryer and Air Lines for Proper Routing, Chaffing, and
Inspect _____ 42–02
Leaks
Lubricate _____ Camshaft Bracket Bushing Lubricating 42–04

00/6 Recreational Vehicle Chassis Maintenance Manual, April 2018

General Information 00
6000 Mile or 6 Month Initial Maintenance: 00–03

Procedure
Performed
6000 Mile (9654 km) or 6 Month Initial Maintenance* MOP
(check off or
initial)
Lubricate _____ Slack Adjuster Lubricating 42–05
Lubricate _____ Foot Brake Valve Actuator Lubricating 42–06
Bendix Hydro-Max® Brake System Inspecting (front-
Inspect _____ 42–07
engine only)
Brake Caliper Slide Pin Lubricating, Bosch Brakes (front-
Lubricate _____ 42–08
engine diesel chassis)
Check _____ Brake Lines Checking, Hydraulic Disc or Air Brakes 42–09
Brake Lining Wear Checking, Hydraulic Disc Brakes
Check _____ 42–10
(front-engine only)
Inspect _____ Brake Inspecting (air brakes) 42–11
Inspect/
_____ Versajust Slack Adjuster Inspection and Lubrication 42–13
Lubricate
Bendix Automatic Drain Valve Operating and Leakage
Inspect _____ 42–14
Tests‡
Drain _____ Air Tanks —
Lubricate _____ Drag Link Lubricating 46–01
Lubricate _____ Steering Driveline Lubricating 46–04
Lubricate _____ Steering Gear Lubricating 46–05
Inspect _____ Fuel Tank Mounts and Fuel Line Checking 47–01
Change _____ Fuel Filters —
Inspect _____ Exhaust System Inspecting 49–01
Check _____ Ground Cables Checking and Cleaning 54–01
Inspect _____ Air Conditioner Component Inspection 83–01
Customer§_____________________________________ Date ____________
* Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchas-
sis.com).
† For vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), which-
ever comes first.
‡ The automatic drain valve should be inspected every 6 months or 1500 operating hours, whichever comes first.
§ Your signature on this form indicates that you have reviewed and agree to the service items to be performed.
Any items you wish to exclude should be indicated with a "no" to the left of that service item.

Recreational Vehicle Chassis Maintenance Manual, April 2018 00/7

00 General Information
15,000 Mile or 12 Month Maintenance: 00–04

Procedure
Performed
15,000 Mile (24 135 km) or 12 Month Maintenance* MOP
(check off or
initial)
Inspect _____ Engine Drive Belt Inspecting 01–01
Check _____ Engine-Support Fasteners Checking 01–02
Engine Oil and Filter (see the engine manufacturer’s
Change _____ —
manual)
Inspect _____ Air Cleaner Inspection 09–01
Charge Air Cooler (CAC) Inspection and Cleaning (if
Inspect _____ 09–02
cleaning is needed)
Inspect _____ Air Compressor Inspection 13–01
Check _____ Alternator, Battery, and Starter Connections Check 15–01
20–01,
Inspect/ Radiator (radiator cap, coolant freeze points, hose routing
_____ 20–02,
Check for chaffing and leaks)
20–03
Lubricate _____ Mechanical Fan Drive Gearbox Lubrication 20–05
Change _____ Transmission Fluid and Filter (if required by Allison) 26–03
Inspect _____ Transmission Hose Routing for Chaffing and Leaks —
Lubricate _____ Throttle Pedal Pivot Pin Lubricating 30–01
Check _____ Suspension Fastener Torque Check 32–01
Check _____ Suspension Height Control Valve Check 32–02
Lubricate _____ ZF IFS Lubrication 32–04
Check _____ Suspension U-Bolt Torque Check 32–06
Inspection_____ V-Ride Rear Suspension Inspection 32–07
Lubricate _____ Knuckle Pin Lubricating† 33–01
Lubricate _____ Tie-Rod End Lubricating and Inspecting† 33–02
Inspect _____ Wheel End Inspecting 33–04
33–05,
Check/ 33–06,
_____ Oil-Filled Hubs Oil Changing (front and tag axle)
Change 35–04,
35–05
Check _____ Axle Seals for Leaks —
Axle Lubricant Changing and Magnetic Plug Cleaning
Change _____ 35–02
(Detroit and Meritor axles)
Check _____ Axle Breather Checking 35–03
Check _____ Tire Pressure —
Lubricate _____ Driveline Inspection and Lubrication 41–01
Inspect _____ Brake System Valves Inspecting 42–01
Air Dryer and Air Lines for Proper Routing, Chaffing, and
Inspect _____ 42–02
Leaks
Lubricate _____ Camshaft Bracket Bushing Lubricating 42–04

00/8 Recreational Vehicle Chassis Maintenance Manual, April 2018

General Information 00
15,000 Mile or 12 Month Maintenance: 00–04

Procedure
Performed
15,000 Mile (24 135 km) or 12 Month Maintenance* MOP
(check off or
initial)
Lubricate _____ Slack Adjuster Lubricating 42–05
Lubricate _____ Foot Brake Valve Actuator Lubricating 42–06
Bendix Hydro-Max® Brake System Inspecting (front-
Inspect _____ 42–07
engine only)
Brake Caliper Slide Pin Lubricating, Bosch Brakes (front-
Lubricate _____ 42–08
engine diesel chassis)
Check _____ Brake Lines Checking, Hydraulic Disc or Air Brakes 42–09
Brake Lining Wear Checking, Hydraulic Disc Brakes
Check _____ 42–10
(front-engine only)
Inspect _____ Brake Inspecting (air brakes) 42–11
Lubricate _____ Meritor Roller Pin Lubricating 42–12
Inspect/
_____ Versajust Slack Adjuster Inspection and Lubrication 42–13
Lubricate
Bendix Automatic Drain Valve Operating and Leakage
Inspect _____ 42–14
Tests‡
Drain _____ Air Tanks —
Lubricate _____ Drag Link Lubricating 46–01
Lubricate _____ Steering Driveline Lubricating 46–04
Lubricate _____ Steering Gear Lubricating 46–05
Inspect _____ Fuel Tank Mounts and Fuel Line Checking 47–01
Change _____ Fuel Filters —
Inspect _____ Exhaust System Inspecting 49–01
Check _____ Ground Cables Checking and Cleaning 54–01
Inspect _____ Air Conditioner Component Inspection 83–01
Customer§_____________________________________ Date ____________
* Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchas-
sis.com).
† For vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), which-
ever comes first.
‡ The automatic drain valve should be inspected every 6 months or 1500 operating hours, whichever comes first.
§ Your signature on this form indicates that you have reviewed and agree to the service items to be performed.
Any items you wish to exclude should be indicated with a "no" to the left of that service item.

Recreational Vehicle Chassis Maintenance Manual, April 2018 00/9

00 General Information
30,000 Mile or 24 Month Maintenance: 00–05

Procedure
Performed
30,000 Mile (48 270 km) or 24 Month Maintenance* MOP
(check off or
initial)
Inspect _____ Engine Drive Belt Inspecting 01–01
Check _____ Engine-Support Fasteners Checking 01–02
Engine Oil and Filter (see the engine manufacturer’s
Change _____ —
manual)
Change _____ Air Cleaner Replacement 09–01
Charge Air Cooler (CAC) Inspection and Cleaning (if
Inspect _____ 09–02
cleaning is needed)
Inspect _____ Air Compressor Inspection 13–01
Check _____ Alternator, Battery, and Starter Connections Check 15–01
20–01,
Inspect/ Radiator (radiator cap, coolant freeze points, hose routing
_____ 20–02,
Check for chaffing and leaks)
20–03
Change _____ Mechanical Fan Drive Gearbox Oil Change 20–04
Lubricate _____ Mechanical Fan Drive Gearbox Lubrication 20–05
Change _____ Transmission Fluid and Filter (if required by Allison) 26–03
Inspect _____ Transmission Hose Routing for Chaffing and Leaks —
Lubricate _____ Throttle Pedal Pivot Pin Lubricating 30–01
Check _____ Suspension Fastener Torque Check 32–01
Check _____ Suspension Height Control Valve Check 32–02
Lubricate _____ ZF IFS Lubrication 32–04
Check _____ Suspension U-Bolt Torque Check 32–06
Inspection_____ V-Ride Rear Suspension Inspection 32–07
Lubricate _____ Knuckle Pin Lubricating† 33–01
Lubricate _____ Tie-Rod End Lubricating and Inspecting† 33–02
Inspect _____ Wheel End Inspecting 33–04
33–05,
Check/ 33–06,
_____ Oil-Filled Hubs Oil Changing (front and tag axle)
Change 35–04,
35–05
Check _____ Axle Seals for Leaks —
Axle Lubricant Changing and Magnetic Plug Cleaning
Change _____ 35–02
(Detroit and Meritor axles)
Check _____ Axle Breather Checking 35–03
Check _____ Wheel Nut Checking 40–01
Check _____ Tire Pressure —
Lubricate _____ Driveline Inspection and Lubrication 41–01
Inspect _____ Brake System Valves Inspecting 42–01

00/10 Recreational Vehicle Chassis Maintenance Manual, April 2018

General Information 00
30,000 Mile or 24 Month Maintenance: 00–05

Procedure
Performed
30,000 Mile (48 270 km) or 24 Month Maintenance* MOP
(check off or
initial)
Air Dryer and Air Lines for Proper Routing, Chaffing, and
Inspect _____ 42–02
Leaks
Lubricate _____ Camshaft Bracket Bushing Lubricating 42–04
Lubricate _____ Slack Adjuster Lubricating 42–05
Lubricate _____ Foot Brake Valve Actuator Lubricating 42–06
Bendix Hydro-Max® Brake System Inspecting (front-
Inspect _____ 42–07
engine only)
Brake Caliper Slide Pin Lubricating, Bosch Brakes (front-
Lubricate _____ 42–08
engine diesel chassis)
Check _____ Brake Lines Checking, Hydraulic Disc or Air Brakes 42–09
Brake Lining Wear Checking, Hydraulic Disc Brakes
Check _____ 42–10
(front-engine only)
Inspect _____ Brake Inspecting (air brakes) 42–11
Lubricate _____ Meritor Roller Pin Lubricating 42–12
Inspect/
_____ Versajust Slack Adjuster Inspection and Lubrication 42–13
Lubricate
Bendix Automatic Drain Valve Operating and Leakage
Inspect _____ 42–14
Tests‡
Drain _____ Air Tanks —
Lubricate _____ Drag Link Lubricating 46–01
Lubricate _____ Steering Driveline Lubricating 46–04
Lubricate _____ Steering Gear Lubricating 46–05
Inspect _____ Fuel Tank Mounts and Fuel Line Checking 47–01
Change _____ Fuel Filters —
Inspect _____ Exhaust System Inspecting 49–01
Check _____ Ground Cables Checking and Cleaning 54–01
Inspect _____ Air Conditioner Component Inspection 83–01
Customer§_____________________________________ Date ____________
* Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchas-
sis.com).
† For vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), which-
ever comes first.
‡ The automatic drain valve should be inspected every 6 months or 1500 operating hours, whichever comes first.
§ Your signature on this form indicates that you have reviewed and agree to the service items to be performed.
Any items you wish to exclude should be indicated with a "no" to the left of that service item.

Recreational Vehicle Chassis Maintenance Manual, April 2018 00/11

00 General Information
45,000 Mile or 36 Month Maintenance: 00–06

Procedure
Performed
45,000 Mile (72 405 km) or 36 Month Maintenance* MOP
(check off or
initial)
Inspect _____ Engine Drive Belt Inspecting 01–01
Check _____ Engine-Support Fasteners Checking 01–02
Engine Oil and Filter (see the engine manufacturer’s
Change _____ —
manual)
Inspect _____ Air Cleaner Inspection 09–01
Charge Air Cooler (CAC) Inspection and Cleaning (if
Inspect _____ 09–02
cleaning is needed)
Inspect _____ Air Compressor Inspection 13–01
Check _____ Alternator, Battery, and Starter Connections Check 15–01
20–01,
Inspect/ Radiator (radiator cap, coolant freeze points, hose routing
_____ 20–02,
Check for chaffing and leaks)
20–03
Lubricate _____ Mechanical Fan Drive Gearbox Lubrication 20–05
Change _____ Transmission Fluid and Filter (if required by Allison) 26–03
Inspect _____ Transmission Hose Routing for Chaffing and Leaks —
Lubricate _____ Throttle Pedal Pivot Pin Lubricating 30–01
Check _____ Suspension Fastener Torque Check 32–01
Check _____ Suspension Height Control Valve Check 32–02
Lubricate _____ ZF IFS Lubrication 32–04
Check _____ Suspension U-Bolt Torque Check 32–06
Inspection_____ V-Ride Rear Suspension Inspection 32–07
Lubricate _____ Knuckle Pin Lubricating† 33–01
Lubricate _____ Tie-Rod End Lubricating and Inspecting† 33–02
Inspect _____ Wheel End Inspecting 33–04
33–05,
Check/ 33–06,
_____ Oil-Filled Hubs Oil Changing (front and tag axle)
Change 35–04,
35–05
Check _____ Axle Seals for Leaks —
Axle Lubricant Changing and Magnetic Plug Cleaning
Change _____ 35–02
(Detroit and Meritor axles)
Check _____ Axle Breather Checking 35–03
Check _____ Tire Pressure —
Lubricate _____ Driveline Inspection and Lubrication 41–01
Inspect _____ Brake System Valves Inspecting 42–01
Air Dryer and Air Lines for Proper Routing, Chaffing, and
Inspect _____ 42–02
Leaks
Change _____ Air Dryer Desiccant and Coalescent Filter Replacing 42–03

00/12 Recreational Vehicle Chassis Maintenance Manual, April 2018

General Information 00
45,000 Mile or 36 Month Maintenance: 00–06

Procedure
Performed
45,000 Mile (72 405 km) or 36 Month Maintenance* MOP
(check off or
initial)
Lubricate _____ Camshaft Bracket Bushing Lubricating 42–04
Lubricate _____ Slack Adjuster Lubricating 42–05
Lubricate _____ Foot Brake Valve Actuator Lubricating 42–06
Bendix Hydro-Max® Brake System Inspecting (front-
Inspect _____ 42–07
engine only)
Brake Caliper Slide Pin Lubricating, Bosch Brakes (front-
Lubricate _____ 42–08
engine diesel chassis)
Check _____ Brake Lines Checking, Hydraulic Disc or Air Brakes 42–09
Brake Lining Wear Checking, Hydraulic Disc Brakes
Check _____ 42–10
(front-engine only)
Inspect _____ Brake Inspecting (air brakes) 42–11
Lubricate _____ Meritor Roller Pin Lubricating 42–12
Inspect/
_____ Versajust Slack Adjuster Inspection and Lubrication 42–13
Lubricate
Bendix Automatic Drain Valve Operating and Leakage
Inspect _____ 42–14
Tests‡
Drain _____ Air Tanks —
Lubricate _____ Drag Link Lubricating 46–01
Lubricate _____ Steering Driveline Lubricating 46–04
Lubricate _____ Steering Gear Lubricating 46–05
Inspect _____ Fuel Tank Mounts and Fuel Line Checking 47–01
Change _____ Fuel Filters —
Inspect _____ Exhaust System Inspecting 49–01
Check _____ Ground Cables Checking and Cleaning 54–01
Inspect _____ Air Conditioner Component Inspection 83–01
Customer§_____________________________________ Date ____________
* Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchas-
sis.com).
† For vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), which-
ever comes first.
‡ The automatic drain valve should be inspected every 6 months or 1500 operating hours, whichever comes first.
§ Your signature on this form indicates that you have reviewed and agree to the service items to be performed.
Any items you wish to exclude should be indicated with a "no" to the left of that service item.

Recreational Vehicle Chassis Maintenance Manual, April 2018 00/13

00 General Information
60,000 Mile or 48 Month Maintenance: 00–07

Procedure
Performed
60,000 Mile (96 540 km) or 48 Month Maintenance* MOP
(check off or
initial)
Inspect _____ Engine Drive Belt Inspecting 01–01
Check _____ Engine-Support Fasteners Checking 01–02
Engine Oil and Filter (see the engine manufacturer’s
Change _____ —
manual)
Change _____ Air Cleaner Replacement 09–01
Charge Air Cooler (CAC) Inspection and Cleaning (if
Inspect _____ 09–02
cleaning is needed)
Inspect _____ Air Compressor Inspection 13–01
Check _____ Alternator, Battery, and Starter Connections Check 15–01
20–01,
Inspect/ Radiator (radiator cap, coolant freeze points, hose routing
_____ 20–02,
Check for chaffing and leaks)
20–03
Change _____ Mechanical Fan Drive Gearbox Oil Change 20–04
Lubricate _____ Mechanical Fan Drive Gearbox Lubrication 20–05
Change _____ Transmission Fluid and Filter (if required by Allison) 26–03
Inspect _____ Transmission Hose Routing for Chaffing and Leaks —
Lubricate _____ Throttle Pedal Pivot Pin Lubricating 30–01
Check _____ Suspension Fastener Torque Check 32–01
Check _____ Suspension Height Control Valve Check 32–02
Lubricate _____ ZF IFS Lubrication 32–04
Check _____ Suspension U-Bolt Torque Check 32–06
Inspection_____ V-Ride Rear Suspension Inspection 32–07
Lubricate _____ Knuckle Pin Lubricating† 33–01
Lubricate _____ Tie-Rod End Lubricating and Inspecting† 33–02
Inspect _____ Wheel End Inspecting 33–04
33–05,
Check/ 33–06,
_____ Oil-Filled Hubs Oil Changing (front and tag axle)
Change 35–04,
35–05
Check _____ Axle Seals for Leaks —
Axle Lubricant Changing and Magnetic Plug Cleaning
Change _____ 35–02
(Detroit and Meritor axles)
Check _____ Axle Breather Checking 35–03
Check _____ Wheel Nut Checking 40–01
Check _____ Tire Pressure —
Lubricate _____ Driveline Inspection and Lubrication 41–01
Inspect _____ Brake System Valves Inspecting 42–01

00/14 Recreational Vehicle Chassis Maintenance Manual, April 2018

General Information 00
60,000 Mile or 48 Month Maintenance: 00–07

Procedure
Performed
60,000 Mile (96 540 km) or 48 Month Maintenance* MOP
(check off or
initial)
Air Dryer and Air Lines for Proper Routing, Chaffing, and
Inspect _____ 42–02
Leaks
Lubricate _____ Camshaft Bracket Bushing Lubricating 42–04
Lubricate _____ Slack Adjuster Lubricating 42–05
Lubricate _____ Foot Brake Valve Actuator Lubricating 42–06
Bendix Hydro-Max® Brake System Inspecting (front-
Inspect _____ 42–07
engine only)
Brake Caliper Slide Pin Lubricating, Bosch Brakes (front-
Lubricate _____ 42–08
engine diesel chassis)
Check _____ Brake Lines Checking, Hydraulic Disc or Air Brakes 42–09
Brake Lining Wear Checking, Hydraulic Disc Brakes
Check _____ 42–10
(front-engine only)
Inspect _____ Brake Inspecting (air brakes) 42–11
Lubricate _____ Meritor Roller Pin Lubricating 42–12
Inspect/
_____ Versajust Slack Adjuster Inspection and Lubrication 42–13
Lubricate
Bendix Automatic Drain Valve Operating and Leakage
Inspect _____ 42–14
Tests‡
Drain _____ Air Tanks —
Lubricate _____ Drag Link Lubricating 46–01
Lubricate _____ Steering Driveline Lubricating 46–04
Lubricate _____ Steering Gear Lubricating 46–05
Inspect _____ Fuel Tank Mounts and Fuel Line Checking 47–01
Change _____ Fuel Filters —
Inspect _____ Exhaust System Inspecting 49–01
Check _____ Ground Cables Checking and Cleaning 54–01
Inspect _____ Air Conditioner Component Inspection 83–01
Customer§_____________________________________ Date ____________
* Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchas-
sis.com).
† For vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), which-
ever comes first.
‡ The automatic drain valve should be inspected every 6 months or 1500 operating hours, whichever comes first.
§ Your signature on this form indicates that you have reviewed and agree to the service items to be performed.
Any items you wish to exclude should be indicated with a "no" to the left of that service item.

Recreational Vehicle Chassis Maintenance Manual, April 2018 00/15

00 General Information
Noise Emission Controls Maintenance: 00–08

Noise Emission Control of design incorporated into any new vehicle for
the purpose of noise control, prior to its sale or
Maintenance delivery to the ultimate purchaser, or while it is in
use.
Federal Law, Part 205: 2. The use of the vehicle after such device or ele-
ment of design has been removed or rendered
Transportation Equipment Noise inoperative by any person.
Emission Controls Among those acts presumed to constitute tam-
Part 205, Transportation Equipment Noise Emission pering are the acts listed below:
Controls, requires the vehicle manufacturer to fur- A. Removal of, or rendering inoperative, the en-
nish, with each new vehicle, such written instructions gine speed governor so as to allow engine
for the proper maintenance, use, and repair of the speed to exceed manufacturer’s specifica-
vehicle by the ultimate purchaser to provide reason- tions.
able assurance of the elimination or minimization of
noise-emission-control degradation throughout the B. Removal of, or rendering inoperative, the fan
life of the vehicle. In compliance with the law, the clutch, including bypassing the control on
noise emission controls maintenance information in any thermostatic fan drive to cause it to op-
each applicable group of this manual, in conjunction erate continuously.
with the chassis workshop manual, provides these
instructions to owners. C. Removal of the fan shroud.
D. Removal of, or rendering inoperative, ex-
Recommendations for haust components, including exhaust pipe
clamping.
Replacement Parts
E. Removal of air intake components.
Replacement parts used for maintenance or repair of
noise emission controls should be genuine Freight-
liner Custom Chassis Corporation (FCCC) parts. If Maintenance Instructions
other than genuine FCCC parts are used for replace-
ment or repair of components affecting noise emis- Scheduled intervals are in the maintenance table in
sion control, the owner should be sure that such this group. A "Verification of Inspections Log (Group
parts are warranted by their manufacturer to be 49)" follows, and should be filled in each time noise
equivalent to genuine FCCC parts in performance emission controls on the vehicle are maintained or
and durability. repaired.

Freightliner Noise Emission

Controls Warranty
See the vehicle owner’s warranty information book
for warranty information concerning noise emission
controls.

Tampering With Noise Controls is

Prohibited
Federal law prohibits the following acts or the caus-
ing thereof:
1. The removal or rendering inoperative by any per-
son (other than for purposes of maintenance,
repair, or replacement) of any device or element

00/16 Recreational Vehicle Chassis Maintenance Manual, April 2018

General Information 00
Verification of Inspections Log: 00–09

Verification of Inspections Log

Verification of Inspections Log, Group 49
Date Mileage Item Cost Maintenance Facility
Group 49—Exhaust System Components

Recreational Vehicle Chassis Maintenance Manual, April 2018 00/17

Engine 01
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Engine Drive Belt Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–01
Engine-Support Fasteners Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–02
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–00

Recreational Vehicle Chassis Maintenance Manual, June 2015

Engine 01

01–00 Safety Precautions 2. Check the 3/4–10 front-engine front mount bolt.
See Fig. 2. Tighten it 95 lbf·ft (128 N·m).
Safety Precautions in this section apply to all Check the 3/4–10 rear-engine front mount bolt.
procedures within this group. Tighten it 95 lbf·ft (128 N·m).

DANGER
When working on the vehicle, shut down the en- 2
gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place
jack stands under the frame rails to ensure the 3
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death.

01–01 Engine Drive Belt

Inspecting 1

11/08/2005 f0120111
WARNING
1. Front and Rear-Engine Rear Mount Bolt
The engine and the belt must be cool before you 2. Engine Mount Bracket-to-Engine Bolts
check the belt. Handling a hot belt can cause per- 3. Frame Mount Bracket Bolts
sonal injury.
Fig. 1, Front and Rear-Engine Rear Mount (ISB chassis
1. Inspect the belt for damage. built after 2002)
Transverse (across the belt width) cracks are
acceptable.
Longitudinal (direction of belt length) cracks that
intersect with transverse cracks are not accept-
able.
2. Replace the belt if it has unacceptable cracks, is
frayed, or has pieces of material missing.
For additional information, see the Cummins Op-
eration and Maintenance Manual.

01–02 Engine-Support 1

Fasteners Checking 11/08/2005 f012110

1. Check the rear engine-support fasteners. See 1. Front and Rear-Engine Front Mount Bolt
Fig. 1. Tighten the rear engine-mount bolt 157 Fig. 2, Front and Rear-Engine Front Mount (ISB chassis
lbf·ft (213 N·m). built after 2002)
Tighten the insulator-to-frame mount bracket
bolts 91 lbf·ft (123 N·m).
Tighten the engine mount bracket-to-engine bolts
62 lbf·ft (84 N·m).

Recreational Vehicle Chassis Maintenance Manual, June 2015 01/1

Air Intake 09
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Air Cleaner Inspection and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–01
Charge Air Cooler (CAC) Inspection and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–02
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–00

Recreational Vehicle Chassis Maintenance Manual, June 2015

Air Intake 09

09–00 Safety Precautions Inspect the air cleaner and plumbing for holes or
tears at the recommended interval. If the air cleaner
is damaged, replace it. See Group 09 of the Recre-
Safety Precautions in this section apply to all
ational Vehicle Chassis Workshop Manual for re-
procedures within this group. moval and installation procedures, or take the vehicle
to an authorized Freightliner dealer. A typical air
DANGER cleaner mounting is shown in Fig. 1.

When working on the vehicle, shut down the en-

gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place
jack stands under the frame rails to ensure the
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death.

09–01 Air Cleaner Inspection

and Replacement

NOTICE
Do not use aftermarket air-cleaner elements. After-
market air-cleaner elements may not seal the
housing correctly, which can lead to engine dam-
age and potentially the loss of warranty. When re-
placing an air-cleaner element, use only the part 07/11/2007 f090451
listed in PartsPro for the serial number of the
vehicle. Fig. 1, Air Cleaner Mounting
IMPORTANT: When first purchased, if the Rec- Engine damage can occur if the air intake system is
reational Vehicle is older than the current model not properly maintained. Use the air intake restriction
year, replace the air filter. indicator to check for air intake system damage or
Due to the variety of possible driving conditions leaks. See Fig. 2. Make sure the engine is off and
note the existing reading on the indicator. Reset the
(dirt roads, paved roads, etc.), it is critical to
indicator by pushing it down. See Fig. 2. Start the
check the air restriction indicator, if so equipped. engine and take a short test drive. Check the indica-
If the vehicle is not equipped with an air restric- tor again and note the level of restriction on the indi-
tion indicator, inspect all components of the air cator, verifying it is at the same level as seen earlier.
intake system and air filter every 12 months. A decrease from the previous level of restriction or a
Replace the air filter every 24 months, or when very low air restriction indicator reading (0 to 4
filter restriction equals or exceeds the maximum inH2O) could indicate an air intake system problem
allowable restriction. More frequent inspec- such as a damaged air filter, loose or disconnected
tions and/or filter replacement may be air intake piping, or a disconnected or damaged air
needed if your vehicle is being operated in a restriction indicator.
dusty environment, to avoid damaging the Replace the air filter at the recommended interval, or
vehicle. when filter restriction equals or exceeds the maxi-
mum allowable restriction. See the Recreational Ve-
NOTE: Remove and visually inspect the air filter hicle Chassis Operator’s Manual for specific restric-
for obvious damage such as holes, cuts, or tion values for your engine. See Group 09 of the
dents. Remove loose debris, such as leaves or Recreational Vehicle Chassis Workshop Manual for
pine needles, from the filter housing.

Recreational Vehicle Chassis Maintenance Manual, June 2015 09/1

09 Air Intake

H20 VACUUM IN H20 VACUUM

25
20
15
10
7

PUSH TO RESET

05/22/97 f090176

Fig. 2, Air Restriction Indicator

removal and installation procedures, or take the ve-

hicle to an authorized Freightliner dealer.

09–02 Charge Air Cooler (CAC)

Inspection and Cleaning
Good airflow through the CAC core is essential for
proper engine cooling. The cores allow air passage,
but form a barrier that tends to collect insects and
airborne debris.
Inspect the CAC hoses for chafing and cracks that
will allow an air leak. Replace the hoses as needed.
Inspect the CAC for clogging or damage and clean
and/or repair it if necessary. Soak the CAC with a
non-corrosive degreaser such as Simple Green. Let
the unit sit for several minutes to work through the
CAC. Using low water pressure directed from the fan
side of the radiator core, rinse the CAC; be careful
not to damage or bend the fins. Depending on the
condition of the CAC, this process may have to be
performed several times.

09/2 Recreational Vehicle Chassis Maintenance Manual, June 2015

Air Compressor 13
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Air Compressor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–01
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–00

Recreational Vehicle Chassis Maintenance Manual, June 2015

Air Compressor 13

13–00 Safety Precautions

Safety Precautions in this section apply to all
procedures within this group.

DANGER
When working on the vehicle, shut down the en-
gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place
jack stands under the frame rails to ensure the
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death.

13–01 Air Compressor

Inspection
1. Inspect the air compressor intake hoses and
connections at the air intake and air compressor
for physical damage. If needed, change the
hoses, and/or tighten or replace the connections.
2. Inspect the coolant supply and return lines for
tight connections. Tighten the connections and
replace the lines and fasteners if needed.
3. For the air governor, inspect the piping and con-
nections for leaks. Replace gaskets and faulty
components as needed.

Recreational Vehicle Chassis Maintenance Manual, June 2015 13/1

Alternators and Starters 15
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Alternator, Battery, and Starter Connections Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–01
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–00

Recreational Vehicle Chassis Maintenance Manual, June 2015

Alternators and Starters 15

15–00 Safety Precautions Trace and inspect all wiring and cables con-
nected to:
Safety Precautions in this section apply to all • alternator
procedures within this group. • starter and depopulation studs
• batteries
DANGER
• magnetic switch
When working on the vehicle, shut down the en- • cab
gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place • jump-start studs
jack stands under the frame rails to ensure the • battery isolation relays
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death. • battery shutoff switches
4. Check wires and cables for wear, chafing, kinks,
discolored insulation, or loose clamps or ties.
15–01 Alternator, Battery, and Find the cause of any problems and repair, re-
Starter Connections place, and reroute wires and clamps as neces-
sary.
Check
IMPORTANT: Ensure that wires and cables are
not near any heat sources; if they are, reroute
WARNING them.
Batteries release explosive gas as a by-product of 5. Clean all circuit breakers and relays.
their chemical activity. Do not smoke when work- 6. Check the alternator wiring for missing insulation,
ing around batteries. Put out all flames and re- kinks, and heat damage. Replace or repair as
move any source of sparks or intense heat. Make needed.
sure the battery compartment is completely
vented before disconnecting or connecting the 7. On the bundled cable that runs from the batteries
battery cables. to the starter, ensure that tie straps are installed
at least every 12 inches (30 cm). Replace any
Battery acid is extremely harmful if splashed in missing tie straps, and add tie straps where
the eyes or on the skin. Always wear a face shield spacing between them exceeds 12 inches (30
and protective clothing when working around bat- cm).
teries.
8. Ensure that all cables have sufficient slack to
Damaged, chafed, or kinked wiring can cause allow for engine movement, and that there is no
electrical short-circuits and lead to fires, causing force on any wiring connectors.
property damage, injury, or death. Clean, inspect,
and maintain wiring and connections carefully. 9. If any convoluted tubing is damaged, check the
wiring inside it. Replace any damaged or missing
1. Disconnect the batteries. convoluted tubing.
2. Check the tightness of the alternator bracket fas- 10. Inspect the battery cables for wear, and replace
teners and alternator mounting fasteners; tighten as needed. Clean the cable connector terminals
the fasteners as needed. For torque values, see with a wire brush. See Group 54 of the vehicle
Group 15 of the vehicle Workshop Manual, or Workshop Manual for troubleshooting instruc-
take the vehicle to an authorized Freightliner tions, and for adjustment, repair, or replacement
dealer. instructions, or take the vehicle to an authorized
3. Check that all electrical connections at the alter- Freightliner dealer.
nator and starter are clean. Clean and tighten all 10.1 Clean and tighten the battery ground
charging system electrical connections as cable, terminal, and clamps.
needed. Spray each electrical connection at the
alternator and starter with dielectric red enamel.

Recreational Vehicle Chassis Maintenance Manual, June 2015 15/1

15 Alternators and Starters

10.2 Inspect the retainer assembly (or battery

hold-downs) and the battery box. Replace
worn or damaged parts. Remove any cor-
rosion with a wire brush, and wash with a
weak solution of baking soda and water.
Rinse with clean water, then dry. Paint
the retainer assembly, if needed, to pre-
vent rusting.
10.3 Check that foreign objects, such as
stones, bolts, and nuts, are removed from
the battery box.
10.4 After cleaning, connect the cables to the
batteries, and tighten them to the torque
specifications listed on the battery, gener-
ally 10 to 15 lbf·ft (14 to 20 N·m).
10.5 Coat the battery terminals with dielectric
grease.
11. Check the terminals on the battery shut-off
switch and the starter relay. Make sure that the
terminal connections are clean and tight. Coat
the terminal connections with dielectric red
enamel after cleaning.

15/2 Recreational Vehicle Chassis Maintenance Manual, June 2015

Engine Cooling/Radiator 20
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Coolant Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–03
Mechanical Fan Drive Gearbox Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–05
Mechanical Fan Drive Gearbox Oil Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–04
Radiator Cap Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–01
Radiator Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–02
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–00

Recreational Vehicle Chassis Maintenance Manual, October 2016

Engine Cooling/Radiator 20

20–00 Safety Precautions

Safety Precautions in this section apply to all
procedures within this group.

20–01 Radiator Cap Check Fig. 1, Surge Tank Coolant Fill Cap

WARNING 20–03 Coolant Replacement

Do not remove or loosen the radiator cap until the At the intervals specified in the maintenance sched-
engine and cooling system have completely ule, or whenever the coolant becomes dirty, flush
cooled. Use extreme care when removing the cap. and refill the cooling system.
A sudden release of pressure from removing the NOTE: The coolant replacement interval is in-
cap prior to the system cooling can result in a creased to 100,000 miles (161 000 km) or 60
surge of scalding coolant that could cause seri- months, whichever comes first. For this interval
ous personal injury.
to apply, you must check and, if necessary, re-
The radiator cap is the most ignored part in the cool- charge the supplemental coolant additive (SCA)
ing system. If it is suspect, replace it. An inspection levels and the freeze point every 25,000 miles
means checking the cap with a pressure tester. A (40 000 km) or 6 months, whichever comes first.
radiator cap in good condition will not open below 9 See the Cummins Operation and Maintenance
psi (62 kPa). A visual check is also in order: look for
signs of deterioration of the inner gasket. Also look
Manual for further information.
for cracks or breaks in the spring retainer in the cap
and for corrosion or deposits on the spring itself. If WARNING
the spring is not in perfect condition, it has probably
lost tension; replace it. See Fig. 1. Do not remove or loosen the radiator cap until the
engine and cooling system have completely
cooled. Use extreme care when removing the cap.
20–02 Radiator Inspection and A sudden release of pressure from removing the
cap prior to the system cooling can result in a
Cleaning surge of scalding coolant that could cause seri-
ous personal injury.
Inspect the radiator for clogging or damage and
clean and/or repair it if necessary. Soak the radiator 1. Drain the cooling system, as follows.
with a non-corrosive degreaser such as Simple 1.1 When the engine is cool, remove the ra-
Green. Let the unit sit for several minutes to work diator cap.
through the radiator. Using low water pressure, rinse
the radiator. Be careful not to damage or bend the Turn the cap slowly counterclockwise until
fins of the radiator. Depending on the condition of the it reaches a "stop." Do not press down
radiator, this process may have to be performed sev- while turning the cap. Wait until any re-
eral times. maining pressure (indicated by a hissing

Recreational Vehicle Chassis Maintenance Manual, October 2016 20/1

20 Engine Cooling/Radiator

sound) is relieved, then press down on 2.9 Disconnect all hoses from the surge tank.
the cap and continue turning it counter- Remove the tank and pour out any fluid.
clockwise. Scrub and clean the inside of the surge
tank with soap and water. Flush it with
1.2 When the cap is removed, run the engine
clean water, then drain it. Install the surge
until the upper radiator hose is hot—this
tank and hoses.
shows that the thermostat is open and
the coolant is flowing through the system. IMPORTANT: On vehicles with EPA07-compliant
engines, the coolant capacity varies depending
WARNING on the engine and accessory installation. After
servicing the cooling system, always verify that
Use extreme care when draining coolant that is the coolant level is between the MIN and MAX
very warm. It may still be hot enough to cause se- lines on the surge tank.
rious personal injury by scalding.
3. Fill the cooling system, as follows.
1.3 Stop the engine. Remove the lower radia-
tor hose to drain the coolant. Drainage 3.1 Slowly add a 50/50 mixture of antifreeze
may be speeded by removing the plug in and water to the surge tank until the sys-
the bottom of the water inlet. tem is filled. Refer to the engine manufac-
turer’s service literature for approved
2. Flush the cooling system, as follows. coolants.
3.2 With the radiator cap removed, start the
NOTICE engine and run it at low idle for 10 sec-
During filling, air must be vented from the engine onds; then at high idle for 1 minute. Re-
coolant passages. Any air trapped in the system turn to low idle.
can cause severe engine damage. 3.3 Run the engine, with the radiator cap re-
2.1 Connect the lower radiator hose and in- moved, until the upper radiator hose is
stall the plug in the bottom of the water hot. With the engine idling, add coolant to
inlet. the radiator until it is between the MIN
and MAX lines on the surge tank. Install
2.2 Open the engine venting petcock. the radiator cap.
2.3 Add water to the surge tank until the sys-
tem is filled.
20–04 Mechanical Fan Drive
2.4 Start the engine. Run it at low idle for 10
seconds, then at high idle for 1 minute. Gearbox Oil Change
Return to low idle.
1. Park the vehicle on a level surface, shut down
2.5 Close the lower petcock when a steady the engine, and set the parking brake. Chock the
stream of water is flowing from it. Don’t tires.
let more than 1.5 quarts (1.4 L) of water
escape. 2. Place a drain pan under the fan drive gearbox.

2.6 Close the upper petcock when a steady IMPORTANT: Label the plugs as they are re-
stream of water is flowing from it. Don’t moved. The breather/fill plug must always be
let more than 1.5 quarts (1.4 L) of water installed in the top of the gearbox, opposite the
escape. drain plug.
2.7 Repeat several times until the drained 3. Remove the drain plug and breather/fill plug,
liquid is nearly colorless. shown in Fig. 2, to begin draining the oil.
2.8 Completely drain the system, then close 4. Remove the oil level plug. See Fig. 2.
the radiator and block the drain valves.
5. Flush the fan drive gearbox with an approved
nonflammalbe, nontoxic solvent such as:

20/2 Recreational Vehicle Chassis Maintenance Manual, October 2016

Engine Cooling/Radiator 20

2 NOTE: If a low-pressure adaptor is not used

with the high-pressure gun, the U-joints may not
1 receive enough lubricant.
3. Using lithium 12-hydroxy stearate grease (NLGI
3 grade 2, with EP additives and meeting ASTM
D4950 LB specifications), lubricate until new
grease can be seen at both U-joint seals.

NOTICE
Fresh lubricant must be seen escaping from both
of the bearing cup seals of each U-joint. If not, the
U-joint may fail prematurely.
5 4
08/31/2011 f200744 4. If the bearing will not take grease, replace the
U-joint assembly.
1. Pinion Shaft 4. Drain Plug
2. Breather/Fill Plug 5. Cross-Shaft 5. Check the old grease. If it appears rusty, gritty, or
3. Oil Level Plug burned, replace the U-joint assembly.
Fig. 2, Mechanical Fan Drive Gearbox 6. Wipe any excess grease from the seals and
grease fittings.
• Lubriplate Syn Flush
• Lubriplate Pure Flush Slip-Joint Spline Lubrication
• Whitmore’s Flushing Oil 1. Check the slip-joints for spline wear by trying to
bend the sleeve-yoke and splined shaft back and
• Medallion™ Flushing Oil Kosher
forth. If looseness is greater than 0.007 inch
6. Using degreaser, clean the thread on the drain (0.18 mm), replace both the sleeve-yoke and the
hole and drain plug. splined shaft.
7. Install the drain plug. 2. Wipe all old grease and dirt from the slip-joint
8. Fill the fan drive gearbox with Mobil® Delvac grease fitting.
75W–90 lubricant until the lubricant starts to 3. Use a hand-type grease gun or a high-pressure
come out of the oil level plug hole. gun with a low-pressure adaptor, to lubricate the
9. Using degreaser, clean the thread on the oil level slip-joint. See Fig. 3. Using lithium 12-hydroxy
and fill holes and both plugs. stearate grease (NLGI grade 2, with EP additives
and meeting ASTM D4950 LB specifications),
10. Install the plugs, making certain that the lubricate until fresh grease appears at the
breather/fill plug is used in the fill plug hole. pressure-relief hole in the yoke plug. Then cover
the relief hole with your finger, while continuing
to lubricate until fresh grease appears at the slip-
20–05 Mechanical Fan Drive joint seal. This ensures complete lubrication of
Gearbox Lubrication the splines.
4. Wipe any excess grease from the pressure-relief
U-Joint Lubrication hole, slip-joint seal, and grease fitting.

1. Wipe all old grease and dirt from each U-joint

grease fitting.
2. Use a hand-type grease gun, or a high-pressure
gun with a low-pressure adaptor, to lubricate the
U-joints. See Fig. 3.

Recreational Vehicle Chassis Maintenance Manual, October 2016 20/3

20 Engine Cooling/Radiator

1 2 1

04/24/2013 f200817
1. U-Joint Grease Fitting 2. Slip-Joint Grease Fitting
Fig. 3, Slip-Joint and U-Joint Lubricating

20/4 Recreational Vehicle Chassis Maintenance Manual, October 2016

Transmission 26
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Allison MD/MH Series Transmission Fluid Level Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–02
Allison Transmission Fluid and Filter Changing (internal/external filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–03
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–00
Transmission Breather Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–01

Recreational Vehicle Chassis Maintenance Manual, June 2015

Transmission 26

26–00 Safety Precautions 26–02 Allison MD/MH Series

Safety Precautions in this section apply to all
Transmission Fluid
procedures within this group. Level Checking
DANGER Cold Check
When working on the vehicle, shut down the en- IMPORTANT: After replacing the transmission
gine, set the parking brake, and chock the tires. fluid or changing the filter(s), it is important to
Before working under the vehicle, always place check the fluid level cold to determine if the
jack stands under the frame rails to ensure the transmission has a sufficient amount of fluid to
vehicle cannot drop. Failure to follow these steps be safely operated until a hot check can be
could result in serious personal injury or death. performed.
1. A cold check may be made when the sump tem-
26–01 Transmission Breather perature is 60 to 104°F (15 to 40°C).
Checking 2. Run the engine for at least one minute to clear
the fluid system of air.
Transmission housing breathers must remain clear. A 3. With the engine running, wipe the dipstick clean
plugged breather could result in pressure build-up, and check the fluid level. Any level within the
which could cause lubricant leakage. COLD RUN (lower) band is satisfactory for oper-
If the breather is plugged, clean or replace it. See ating the vehicle. See Fig. 2. If the level is not
Fig. 1. Check more often if the vehicle is operating within the COLD RUN band, add or drain fluid
under very dusty conditions. until it reaches the middle of the COLD RUN
band.

11/16/2000 f270074

Fig. 2, Transmission Dipstick

4. Perform a hot check at the first opportunity after

normal operating temperature, 160 to 200°F (71
05/27/93 f260007a to 93°C), is reached.

Fig. 1, Transmission Breather Hot Check

Recommended Method
With the vehicle on a level surface and the transmis-
sion in neutral at operating temperature, perform the
steps below.

Recreational Vehicle Chassis Maintenance Manual, June 2015 26/1

26 Transmission

1. On the transmission shift selector, press the up NOTE: The fluid must be warm to ensure an
and down arrow keys simultaneously. See Fig. 3. accurate check. The fluid level rises as tempera-
ture increases.
1 2. Park the vehicle. Shift to Neutral (N) and apply
the parking brake. Let the engine run at idle.
S
E
L
M
O
N
3. Wipe the dipstick clean and check the fluid level.
I
E
C
T
T
O
R
A safe operating level is any level within the HOT
RUN (upper) band on the dipstick. See Fig. 2.
4. If the fluid is not within this range, add or drain
R MODE
fluid as needed to bring the level to the top of
the HOT RUN band. See Table 1 for approved
N transmission lubricants. See Table 2 for lubricant
capacities.
D
26–03 Allison Transmission
Fluid and Filter
03/04/2008 f270159 Changing (internal/
1. Shift Selector Display Screen external filter)
Fig. 3, Transmission Shift Selector IMPORTANT: For oil and filter change intervals,
2. Release the arrow keys and wait for a two- see the applicable Allison Operator’s Manual. To
minute countdown. request a replacement Allison Operator’s
Manual, call 1-888-666-5799.
3. The transmission shift selector display screen will
display one of the following messages. Oil and filter change intervals can also be found
• OL - OK indicates an acceptable oil level. at www.allisontransmission.com. Choose
"Service", and click "Service Tips". Then, select
• OL - HI followed by a number indicates the the appropriate transmission to view fluid and
amount that is over-filled.
filter change recommendations.
• OL - LO followed by a number indicates
the amount that is under-filled.
• OL - 70 indicates that the transmission is
not up to operating temperature.

Alternate Method
1. Operate the transmission in a Drive (D) range
until normal operating temperature, 160 to 200°F
(71 to 93°C), is reached.

Approved Allison Transmission Lubricants*

TES-295 Approval
Company Product Brand Name
Number
AN-051005 ExxonMobil Lubricants and Petroleum Specialties Company Mobil Delvac Synthetic ATF
AN-011001 Castrol Heavy Duty Lubricants TranSynd
AN-031002 BP Autran Syn 295

26/2 Recreational Vehicle Chassis Maintenance Manual, June 2015

Transmission 26

Approved Allison Transmission Lubricants*

TES-295 Approval
Company Product Brand Name
Number
AN-031003 Cognis Corporation Emgard 2805
AN-031004 International Truck & Engine Company Fleetrite Synthetic ATF
AN-071006 John Deere & Company HD SynTran
* To check the latest Allison approved fluids, go to www.allisontransmission.com. Lubricants listed in order of preference. Do not mix types of oil.

Table 1, Approved Allison Transmission Lubricants

Automatic Transmission Lubricant Capacities

Refill Capacity*:
Model
qt (L)
1000, 2000, and 2000 MH 16.0 (15.1)
3000 MH† and 4000 MH 17.5 (16.5)
* Quantities listed are approximate. Add the recommended amount of fluid
as listed under refill capacity. Do not overfill.
† Some Allison 3000 MH transmissions have a deeper oil sump than other
models. These models require 3 additional quarts (2.8 L) of ATF.
Table 2, Automatic Transmission Lubricant
Capacities

Recreational Vehicle Chassis Maintenance Manual, June 2015 26/3

Throttle Control 30
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Throttle Pedal Pivot Pin Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30–01

Recreational Vehicle Chassis Maintenance Manual, January 2010

Throttle Control 30

30–01 Throttle Pedal Pivot Pin

Lubricating
Using a silicone spray, lubricate the throttle pedal
pivot pins as shown in Fig. 1 and Fig. 2.

3
1
07/09/2009 f300408a
2
1. Throttle Pedal 2. Pivot Pins
Assembly 3. Base Plate
Fig. 1, Floor-Mounted Throttle Pedal 07/09/2009 f300409a

1. Throttle Pedal Assembly

2. Pivot Pin (not shown)
Fig. 2, Suspended Throttle Pedal

Recreational Vehicle Chassis Maintenance Manual, January 2010 30/1

Suspension 32
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Neway Suspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–03
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–00
Suspension Fastener Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–01
Suspension Height Control Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–02
Suspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–05
Suspension U-Bolt Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–06
V-Ride Rear Suspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–07
ZF IFS Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–04

Recreational Vehicle Chassis Maintenance Manual, June 2015

Suspension 32

32–00 Safety Precautions NOTICE

Safety Precautions in this section apply to all Failure to retorque the U-bolt nuts could result in
procedures within this group. spring breakage and abnormal tire wear.
4. Remove the safety stands and lower the vehicle
DANGER to the ground.
When working on the vehicle, shut down the en-
gine, set the parking brake, and chock the tires. 32–02 Suspension Height
Before working under the vehicle, always place
jack stands under the frame rails to ensure the
Control Valve Check
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death. WARNING
32–01 Suspension Fastener Inspect the height control components and check
their operation. Failure to perform these inspec-
Torque Check tions and checks could result in separation of
worn suspension components and loss of vehicle
control, possibly causing personal injury or death,
WARNING or property damage.
Inspect the suspension fasteners. Failure to per- 1. Park the vehicle on a level surface. Apply the
form inspections could result in separation of parking brake and chock the tires to prevent the
worn suspension components and loss of vehicle vehicle from moving.
control, possibly causing personal injury or death, 2. Inspect the front and rear suspensions for any
or property damage. signs of damage, loose components, wear, or
1. Chock the front or the rear tires. Working at the cracks. Replace any damaged components to
front of the vehicle or at the rear of the vehicle, prevent failure or equipment breakdown.
raise the vehicle so that the tires just clear the 3. Inspect all bolts and nuts at the pivot axle con-
ground and the suspension is fully extended. nections to assure that they are properly torqued.
Place safety stands under the vehicle frame. Check all other nuts and bolts for proper torque.
2. Check the suspension fasteners. See Table 1 for See Group 00 of this manual for proper torque
correct fastener torques. specifications.
3. Check the torque of the rear axle U-bolts. 4. Check the air pressure gauge to confirm that
there is in excess of 65 psi (448 kPa) in the air
In a diagonal pattern, tighten all 5/8–18 U-bolt system, and inspect the air springs for sufficient
nuts 205 lbf·ft (278 N·m); tighten all and equal firmness.
3/4–16 U-bolt nuts 300 lbf·ft (407 N·m); and
tighten all 7/8–14 U-bolt nuts 460 lbf·ft (624
N·m).

Suspension Torque Specifications (lubricated threads)

Description Size Torque: lbf·ft (N·m)
Shock Absorber Mount Locknut 3/4–16 110 to 150 (149 to 203)
Air Spring Upper Mounting Plate Locknut 3/4–16 31 to 42 (42 to 57)
Air Spring Upper Mounting Plate Capscrew 1/2–13 31 to 42 (42 to 57)
Air Spring Lower Mounting Plate Capscrew 1/2–13 31 to 42 (42 to 57)
Transverse Beam Bushing Locknuts 1-1/4–12 600 to 700 (814 to 949)

Recreational Vehicle Chassis Maintenance Manual, June 2015 32/1

32 Suspension

Suspension Torque Specifications (lubricated threads)

Description Size Torque: lbf·ft (N·m)
Equalizing Beam Center Bushing Locknut 3/4–16 150 to 200 (203 to 271)
1-1/8–12
Equalizing Beam Front Bushing Locknut 600 to 700 (814 to 949)
1-1/4–12
Control Rod Ball Stud Locknut 1-1/8–12 550 to 650 (746 to 881)
Control and Torque Rod Mounting Locknuts 5/8–18 110 to 150 (149 to 203)
Table 1, Suspension Torque Specifications (lubricated threads)

NOTE: Height control valves control all front and 32–03 Neway Suspension
rear suspension air springs. Check for air leaks
by applying a soapy solution. Then, check for Inspection
bubbles at all air connections and fittings.
5. Check the ride height of the air suspension by WARNING
measuring the distance from the center of the
lower shock bolt to the bottom of the frame rail. Inspect the components and check their operation
See Fig. 1. See Table 2 for height control valve as described below. Failure to perform these in-
adjustment measurements. If ride height is incor- spections and checks could result in separation of
rect, adjust the air suspension. worn suspension components and loss of vehicle
control, possibly causing personal injury or death,
Height Control Valve Adjustment Measurements or property damage.
Measurement 1. Chock the front or the rear tires. Working at the
Suspension
Inches ±1/4 (mm ±6) front of the vehicle or at the rear of the vehicle,
10 (254) or raise the vehicle so that the tires just clear the
AS120 (front) ground and the suspension is fully extended.
10-1/2 (267)*
Place safety stands under the vehicle frame.
AS140 (front) 11 (279)
2. Squeeze all air springs to check for complete
IFS114 (front) 17-1/2 (445)
deflation. It may take ten minutes for the pres-
IFS ZF (front) 15-3/4 (400) sure to bleed down from the air spring. See
ADL-RS17/19/21 10-1/4 (260) Fig. 2. If any air springs remain partially or fully
inflated, see Group 32 of the Recreational Ve-
AD200-RS17/19 9-3/4 (248) hicle Chassis Workshop Manual, or take the ve-
AD200-RS15 9-3/8 (238) hicle to an authorized Freightliner dealer. Inspect
ADTB280 (rear) 17-1/4 (438)
the air springs for cracks, tears, or other dam-
age.
Airliner 15k (rear) 8-3/4 (222)
3. Inspect each air spring for wear at the pedestal
AD123 (rear) 18 (457) connection. Inspect for leaks at the upper and
ADL123 (rear) 11 (279) lower pedestal connections using a soapy solu-
* Some vehicles have a different shock location. When this is the case, the tion. Replace any worn air springs; for instruc-
vehicle will have a 55 degree wheel cut. Ride height for these vehicles tions, see Group 32 of the Recreational Vehicle
should be set at 10-1/2 inches (267 mm). Chassis Workshop Manual, or take the vehicle to
Table 2, Height Control Valve Adjustment an authorized Freightliner dealer.
Measurements
4. Inspect the bolts and nuts at the pivot connec-
tions, the transverse beam connections, and the
axle connections to ensure they are tightened to
the correct torque specification.

32/2 Recreational Vehicle Chassis Maintenance Manual, June 2015

Suspension 32

3 2

09/28/98 f320423a
A. Measure here for suspension ride height.
1. Frame Rail 2. Axle Housing 3. Axle Centerline
Fig. 1, Ride Height Inspection (typical Neway suspension shown)

5. Check all of the other suspension components reational Vehicle Chassis Workshop Manual, or
for any sign of damage, looseness, wear, or take the vehicle to an authorized Freightliner
cracks. Replace worn or damaged parts. See dealer.
Group 32 of the Recreational Vehicle Chassis
9. Check for leaks on the height control valves by
Workshop Manual, or take the vehicle to an au- applying a soapy solution, then, watching for
thorized Freightliner dealer.
bubbles at all air connections and fittings.
6. Inspect for cracked welds. If cracks are found,
10. Inspect the shock absorbers for oil leaks and
contact Neway immediately for further instruc-
worn rubber bushings. Replace the shock ab-
tions.
sorbers and/or rubber bushings if wear or dam-
7. Inspect the torque rod and track bar pivot bush- age is noted. For instructions, see Group 32 of
ings for excessive wear. Replace worn or dam- the Recreational Vehicle Chassis Workshop
aged bushings. See Group 32 of the Recre- Manual, or take the vehicle to an authorized
ational Vehicle Chassis Workshop Manual, or Freightliner dealer.
take the vehicle to an authorized Freightliner
11. Remove the safety stands and lower the vehicle
dealer.
to the ground. Run the engine until air pressure
8. Move the axle up and down while checking for of at least 100 psi (689 kPa) is maintained
signs of looseness due to worn parts at the front throughout the system.
pivot connections. Replace any worn parts by
following the procedures in Group 32 of the Rec- IMPORTANT: Repeat this check at both ends of
the vehicle.

Recreational Vehicle Chassis Maintenance Manual, June 2015 32/3

32 Suspension

02/21/2005 f321032

Fig. 2, Holland Neway ADL 120/123 Suspension

12. Check that all air springs are inflated. If the air
springs do not inflate, see Group 32 of the Rec- WARNING
reational Vehicle Chassis Workshop Manual for
possible causes and corrections, or take the ve- Never work around or under a vehicle that is sup-
hicle to an authorized Freightliner dealer. ported only by a jack. Always support the vehicle
with safety stands. Jacks can slip, causing the
vehicle to fall, which could result in serious injury
32–04 ZF IFS Lubrication or death.
IMPORTANT: ZF recommends checking the
IMPORTANT: Do not raise the vehicle by plac- wheel bearing lash and adjusting as needed
ing a jack under the control arm(s). The weight every 50,000 miles (80 450 km).
of the vehicle could damage the control arms
and cause alignment issues. See Fig. 3 for cor- 2. Remove the wheel hub. See Group 33 of the
rect jack placement. Recreational Vehicle Chassis Workshop Manual
for wheel bearing service procedures, or take the
1. Chock the rear tires and apply the parking brake. vehicle to an authorized Freightliner dealer.
Raise the front of the vehicle with a jack so the
tires just clear the ground and the suspension is 3. Lubricate the steering knuckle/control arm at indi-
fully extended. Place safety stands under the cated maintenance intervals. Use only an NLGI
vehicle frame. Grade 2 lithium-based grease, multipurpose

32/4 Recreational Vehicle Chassis Maintenance Manual, June 2015

Suspension 32

grease, or mineral oil on the lubricating points.

See Fig. 4 and Fig. 5.
32–05 Suspension Inspection

08/13/2013 f321166

Fig. 3, ZF IFS Jack Placement

2
1
2

09/30/2004 4 3 f321019

1. Steering Knuckle Bearing Grease Fitting (upper)

3
2. Control Arm Grease Fitting (upper)
09/30/2004 f321018 3. Control Arm Grease Fitting (lower)
4. Steering Knuckle Bearing Grease Fitting (lower)
1. Steering Knuckle Bearing Grease Fitting (upper)
2. Steering Knuckle Fig. 5, Pressure Grease Fitting Positions, RL-75EM
3. Steering Knuckle Bearing Grease Fitting (lower)
Fig. 4, Pressure Grease Fitting Positions, RL-75E Freightliner Spring Front and
Rear Suspension Spring
Assemblies Inspection
Inspect the front and rear suspension spring assem-
blies for pitted, cracked, broken, or abnormally bent
leaves and extreme rust. If any of these conditions
exist, replace the spring assembly. See Group 32 of

Recreational Vehicle Chassis Maintenance Manual, June 2015 32/5

32 Suspension

the Recreational Vehicle Chassis Workshop Manual Inspect the rear shackle brackets for bushing wear or
for instructions, or take the vehicle to an authorized cracks.
Freightliner dealer. Inspect the stabilizer bar, if present, for irregular
bushing wear or cracks in the brackets. Check the
WARNING rubber helper spring, if present, for cracks.
Do not replace individual leaves of a damaged leaf
spring assembly; replace the complete spring as- 32–06 Suspension U-Bolt
sembly. Visible damage (cracks or breaks) to one
leaf causes hidden damage to other leaves. Re-
Torque Check
placement of only the visibly damaged part(s) is
Check the U-bolt torque of both the front and rear
no assurance that the spring is safe. On front
axles where applicable.
spring assemblies, if cracks or breaks exist in the
two top leaves, a loss of vehicle control could
occur. Failure to replace a damaged spring assem- NOTICE
bly could cause an accident resulting in property
damage, serious personal injury, or death. Failure to retorque the U-bolt nuts could result in
spring breakage and abnormal tire wear.
IMPORTANT: On multi-leaf suspensions, closely
inspect each component of the leaf spring as- 1. Park the vehicle on a flat surface, apply the park-
ing brake, and chock the tires.
semblies, including the brackets, U-bolts, and
related parts. 2. Check the U-bolt torque in a diagonal pattern.
See Fig. 6. Set a click-type torque wrench to the
60-Inch Taper-Leaf Spring highest torque value for the fastener being
checked. See Table 3 for U-bolt torque specifica-
Component Check tions. Turn the wrench in a clockwise motion
(looking up) until the torque wrench clicks.
No lubrication is required on the 60-inch taper-leaf
spring front and rear suspension. 3. Remove the chocks.

U-Bolt Torque Values

Torque:
Description Size
lbf·ft (N·m)
Stage 1: Hand tighten
Stage 2: 60 (81)
5/8–18
Stage 3: 200 (271)
Stage 4: 180 to 230 (244 to 312)
Spring Assembly U-Bolt High Nuts*
Stage 1: Hand tighten
Stage 2: 60 (81)
3/4–16
Stage 3: 200 (271)
Stage 4: 270 to 330 (366 to 447)
* Tighten in the sequence shown in Fig. 6.

Table 3, U-Bolt Torque Values

inspected for wear or damage, and replaced if

32–07 V-Ride Rear Suspension needed. These components include:
Inspection • air spring
Along with the specific V-Ride suspension instruc- • air supply (pneumatic components)
tions provided, all suspension components should be • apex bracket

32/6 Recreational Vehicle Chassis Maintenance Manual, June 2015

Suspension 32

1
could be worn and a pivot bushing physical in-
4
spection is required.
• If the pivot bushing shows signs of torn, sepa-
rated, or disconnected rubber, as shown in
Fig. 7, it could be the result of axle misalign-
ment. If this condition is evident, a pivot bushing
physical inspection is required.
• If the outer rubber flange(s) is missing, or there
2 3 are shards of rubber visible, as shown in Fig. 7,
10/05/2016 f320783 it could be the result of axle misalignment. If this
condition is evident, the pivot bushing must be
Fig. 6, Tightening Sequence for U-Bolt High Nuts replaced.
• fasteners
• frame hanger assembly
• QUICK-ALIGN connection
1 2 2
• shock absorbers 1 3
• torque rods 04/15/2014 f321190

• U-beam assembly 1. Torn Rubber

2. Disconnected Rubber Flange
3. Missing Rubber Flange
WARNING
Fig. 7, Inspecting for Torn, Disconnected, or Missing
The pivot bushing and D-pin bushing are critical Rubber Flange
components of the V-Ride rear air suspension. If
any components appear damaged or worn, the Pivot Bushing Physical
component must be replaced. Failure to replace
worn or damaged components can result in the Inspection
deformation of parts, loss of clamp force, bolt fail- 1. Remove the U-beam assembly. For instructions,
ure, loss of axle alignment, loss of vehicle control, see Section 32.05, Subject 140 in the Recre-
property damage, or personal injury. ational Vehicle Chassis Workshop Manual.
There are two types of pivot bushing inspections for 2. After removal, inspect the pivot bushing connec-
the V-Ride suspension. The pivot bushing can be tions and inner metal areas.
visually inspected by looking at the outer rubber
flange(s) of the bushing. If the visual inspection war- 3. No replacement is needed if the pivot bushing
rants, a physical inspection can be conducted in exhibits a tight joint. See Fig. 8. An imprinted
which disassembly is required. two-line wear pattern on the bushing inner metal
indicates the pivot bushing is securely clamped
in the frame hanger.
Pivot Bushing Visual Inspection
4. Inspect the pivot bushing. See Fig. 9. Any of the
To perform a visual inspection of the pivot bushing, it following items could be the result of axle mis-
is not necessary to disassemble the pivot bushing alignment or loose fasteners and require replace-
connection. If the pivot bushing rubber flange(s) are ment of the pivot bushing:
intact and there are no signs of metal-to-metal con-
tact, the bushing does not require replacement. • an elongated or damaged bore

• The U-beam assembly is designed with the • distorted, separated, or torn rubber
pivot bushings centered in each U-beam end • signs of rust
hub. If the pivot bushing is not centered in each
5. Inspect the inside of the frame hanger legs and
hub, it is an indication that the pivot bushing
the QUICK-ALIGN collars. If any of the following

Recreational Vehicle Chassis Maintenance Manual, June 2015 32/7

32 Suspension

D-Pin Bushing Visual Inspection

It is not necessary to disassemble the D-pin connec-
tion to perform a visual inspection of the D-pin bush-
ing. The D-pin bushing is designed with a layer of
rubber in the bushing. It is acceptable to see a bead
of rubber protruding from the bushing. See Fig. 10.

1
04/15/2014 f321191
04/15/2014 f321193

Fig. 8, Good Joint with an Imprinted Two-Line Wear 1. Bead of Rubber

Pattern
Fig. 10, Acceptable D-Pin

D-pin bushing replacement is required when metal-

to-metal contact wear marks on the D-pin outer metal
are evident, or the D-pin outer metal is distorted. See
Fig. 11.
3
1 2
04/15/2014 f321192 V-Rod Assembly Inspection
NOTE: All of these examples exhibit a loose joint.
WARNING
1. Elongated/Damaged Bore
2. Distorted Rubber The V-Ride rear air suspension incorporates
3. Rust V-torque rods for vehicle stability. If these compo-
Fig. 9, Inspecting for Indications of a Loose Joint nents are disconnected or are non-functional, the
vehicle should not be operated. Failure to do so
are present, the pivot bushing and one or more can result in adverse vehicle handling and pos-
of the mating components may require replace- sible tire contact with the frame. Operating a ve-
ment: hicle with non-functional V-torque rods can result
in the loss of vehicle control, severe personal in-
• Evidence of wear marks on the inside of
jury, and component damage.
the frame hanger legs indicating metal-to-
metal contact or movement. NOTE: Grade 8 bolts and Grade C locknuts are
• The snout of the QUICK-ALIGN concentric recommended for all torque rod attachments.
or eccentric collar is elongated or dam- 1. Visually inspect the torque rod bushing for metal-
aged. to-metal contact. Inspect for bent, cracked, or
6. Check the suspension alignment and adjust if broken torque rods, and for end hubs with an
necessary. For instructions, see Section 32.05 in elongated oval shape. Any of these conditions
the Recreational Vehicle Chassis Workshop require component replacement.
Manual. 2. Inspect the torque rods for looseness. With the
vehicle shut down, a lever check can be per-

32/8 Recreational Vehicle Chassis Maintenance Manual, June 2015

Suspension 32

1
1 2

3
04/15/2014 f321195

1. Torque Rod Assembly

2. Torque Rod Shims
3. V-Rod Bracket
2
Fig. 12, V-Rod Assembly

04/15/2014 f321194

1. Distorted Outer Metal

2. Evidence of Metal-to-Metal Contact
Fig. 11, Unacceptable D-Pin

formed with a long pry bar placed under each

rod end and pressure applied.
NOTE: Torque rod length is determined by the
vehicle manufacturer to center the axles under
the frame.
If the lateral alignment of the axles is incorrect,
it may be necessary to shim the torque rod end
that attaches to the V-rod bracket. See Fig. 12.
For lateral alignment instructions, see Section
32.05, Subject 180 in the Recreational Vehicle
Chassis Workshop Manual.
3. Inspect the V-rod bracket for cracks, movement,
or damage and replace the V-rod bracket if
needed.
The torque rod may be renewed by pressing out
the worn bushings and replacing them. For in-
structions, see Section 32.05, Subjects 120 and
130 in the Recreational Vehicle Chassis Work-
shop Manual.

Recreational Vehicle Chassis Maintenance Manual, June 2015 32/9

Front Axle 33
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

All-Axle Alignment Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–03
Knuckle Pin Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–01
Oil-Filled Hubs Oil Changing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–06
Oil-Filled Hubs Oil Level Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–05
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–00
Tie-Rod End Lubricating and Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–02
Wheel End Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–04

Recreational Vehicle Chassis Maintenance Manual, June 2015

Front Axle 33

33–00 Safety Precautions

1
Safety Precautions in this section apply to all
procedures within this group.

33–01 Knuckle Pin Lubricating

NOTICE
Use regulated pressure when lubricating the
knuckle assemblies, otherwise damage could re-
sult to the knuckle caps.

Detroit™ Axles B 1
On the front axle, grease fittings are on the top and 06/07/2012 f330272
bottom caps of each knuckle.
A Upper View, LH Side B Lower View, LH Side
1. Park the vehicle on a level surface, shut down 1. Grease Fitting
the engine, and set the parking brake. Chock the
tires. When lubricating upper and lower knuckle Fig. 1, Grease Fittings, Detroit Axles
assemblies, do not raise the front axle.
2. Wipe the grease fittings clean.
3. Apply multipurpose chassis grease, NLGI Grade
1 (6% 12-hydroxy lithium stearate grease) or
NLGI Grade 2 (8% 12-hydroxy lithium stearate
grease), until new grease is seen at the junctions
of the axle beam and knuckles. For locations of
grease fittings, see Fig. 1; for grease exit points,
see Fig. 2.

Meritor Axles 09/13/2012 f330275

Hold a high-pressure grease gun on each fitting until
fresh grease appears. See Fig. 3. This will ensure Fig. 2, Kingpin Grease Exit Points, Detroit Axles
that all of the old contaminated grease has been ing area while turning the wheels from extreme right
forced out. to left, and back again (lock-to-lock). This will elimi-
When lubricating Meritor axle knuckle pin bushings at nate small air pockets and improve grease distribu-
the initial maintenance (IM) interval, first wipe the tion.
lube fittings clean. Then, slowly feed multipurpose
chassis grease (NLGI grade 1 or 2) into each bush-

Recreational Vehicle Chassis Maintenance Manual, June 2015 33/1

33 Front Axle

1. For any Detroit or Meritor axle that requires lubri-

1 cation of the tie-rod ends, wipe the grease fit-
tings clean, then pump multipurpose chassis
grease, NLGI Grade 1 (6% 12-hydroxy lithium
stearate grease) or NLGI Grade 2 (8% 12-
hydroxy lithium stearate grease), into the tie-rod
ends until all used grease is forced out and fresh
grease is seen at the ball stud neck. See Fig. 4.
A

2
09/06/96 1 f320032a
Pump lubricant into each grease fitting until fresh grease
comes out at A.
1. Grease Fitting
1
06/12/2012 f330273
Fig. 3, Meritor Axle Grease Fittings
NOTE: No grease should emit from the tie-rod boot. If
NOTE: The grease seal will accept the grease grease emits from the tie-rod boot, the boot is dam-
pressure without damaging the seal, and is de- aged.
signed to have grease pumped out through it 1. Grease Fitting 2. Boot
during lubrication. Even if grease leaks out
Fig. 4, Grease Fitting and Boot (Detroit axle shown)
around the top or bottom plate, continue pump-
ing until new grease is seen at the seal on the NOTE: Inspect the tie-rod end boots for cracks,
bushing opposite the grease fitting. wear, or damage. If a boot is cracked, worn, or
When lubricating knuckle pin bushings after the IM damaged, replace the tie-rod assembly.
maintenance interval, first wipe the lube fittings 2. Inspect the tie-rod ends, as follows.
clean. Then apply multipurpose chassis grease until
new grease is seen at the grease seal on the bush- 2.1 Shake the cross-tube. Movement or
ing opposite the fittings. looseness between the tapered shaft of
the ball and the cross-tube socket mem-
bers means that the tie-rod end assembly
33–02 Tie-Rod End Lubricating must be replaced.
and Inspecting 2.2 The threaded portion of the tie-rod end
assembly must be inserted all the way
IMPORTANT: DOT roadside tie-rod assembly into the cross-tube split for adequate
replacement criteria specifies that if tie-rod end- clamping. See Fig. 5. Replace the parts if
this cannot be done. For instructions, see
play is 1/8 inch (3 mm) or greater, measured on the axle manufacturer’s service manual.
the road, the vehicle must be taken out of ser-
vice immediately. If less than 1/8 inch (3 mm), 2.3 Check the tie-rod end nut and clamp nut
the vehicle does not have to be taken out of torques. For Meritor axles, tighten the tie-
service but a major out-of-service inspection rod end nut 100 lbf·ft (136 N·m), and
tighten the clamp nut 40 to 55 lbf·ft (54 to
and maintenance must be scheduled as soon 75 N·m). For Detroit axles, see Table 1
as possible. for tie-rod end nut torque specifications

33/2 Recreational Vehicle Chassis Maintenance Manual, June 2015

Front Axle 33

33–03 All-Axle Alignment

OK Checking
NOTE: The final stage manufacturer is respon-
sible for setting the vehicle ride height with air
suspension and some vehicle alignments. On
full-railed chassis, this includes the final toe-in
setting on the front axle. For modular style
1 chassis, both the front axle toe-in and rear axle
thrust angle settings are included.
OK Drive Axle Alignment Checking
NOTE: The maximum tolerance from perpen-
dicular for rear axle alignment should be ±0.25
degree.
Check the axle alignment, parallelism, and thrust
angle measurements for the rear axle. Use the appli-
02/27/2007 f320033a cable procedure and specifications in Group 35 of
IMPORTANT: The tie-rod end threads must be visible the Recreational Vehicle Chassis Workshop Manual,
throughout the entire length of the split. or take the vehicle to an authorized Freightliner
NOTE: Pinch bolt not shown to provide clarity. dealer.
1. Cross-Tube Split
Toe-In Inspection
Fig. 5, Tie-Rod End Adjustment
For vehicle alignment to be accurate, the shop floor
and Table 2 for tie-rod end clamp nut must be level in every direction. The turn plates for
torque specifications. the front wheels must rotate freely without friction,
and the alignment equipment must be calibrated
Detroit Axle Tie-Rod End Nut every three months by a qualified technician from the
equipment manufacturer. Freightliner dealers must
Thread Torque: lbf·ft (N·m) have proof of this calibration history.
5/8–16 60 to 115 (81 to 156)
NOTE: Toe-in should be within 0 to 1/32 inch
5/8–18 60 to 115 (81 to 156) (0.8 mm).
3/4–16 90 to 170 (122 to 230) 1. Apply the parking brake, and chock the rear
7/8–14 160 to 300 (217 to 407) tires.
Table 1, Detroit Axle Tie-Rod End Nut 2. Raise the front of the vehicle until the tires clear
the ground. Check that the safety stands will
support the combined weight of the body, axle,
Detroit Axle Tie-Rod End Clamp Nut and frame. Place safety stands under the axle.
Thread Torque: lbf·ft (N·m) 3. Using spray paint or a piece of chalk, mark the
1/2–13 35 to 45 (47 to 61) entire center rib of each front tire.
5/8–11 40 to 60 (54 to 81) 4. Place a scribe or pointed instrument against the
5/8–18 50 to 64 (73 to 87) marked center rib of each tire, and turn the tires.
Hold the scribe firmly in place so that a single
3/4–10 155 to 175 (210 to 237) straight line is scribed all the way around each
Table 2, Detroit Axle Tie-Rod End Clamp Nut front tire.

Recreational Vehicle Chassis Maintenance Manual, June 2015 33/3

33 Front Axle

5. Place a turn-plate or turntable under both front

tires. Remove the safety stands from underneath
the axle, then lower the vehicle. Remove the
lockpins from the gauges; make sure that the
tires are pointing straight ahead.
NOTE: If turn-plates or turntables are not avail-
able, lower the vehicle. Remove the chocks
from the rear tires and release the parking
brake. Move the vehicle backward and then for-
ward about six feet (two meters).
10/05/2016 f330014a
6. Place a trammel bar at the rear of the front tires;
locate the trammel pointers at spindle height, Fig. 7, Trammel Bar Positioning
and adjust the pointers to line up with the scribe
lines on the center ribs of the front tires. See
Fig. 6. Lock the pointers in place. Check that the
scale is set to zero.

B
10/05/2016 f330082a
NOTE: B minus A equals toe-in.
Fig. 6, Wheel Toe-In (overhead view)

7. Place the trammel bar at the front of the tires 10/05/2016 f400100a
and adjust the scale end so that the pointers line
up with the scribe lines. See Fig. 7 and Fig. 8. Fig. 8, Setting Trammel Bar Pointers
8. Read the toe-in from the scale, and compare it to
the toe-in specification in Group 33 of the Recre- 33–04 Wheel End Inspection
ational Vehicle Chassis Workshop Manual, or
take the vehicle to an authorized Freightliner IMPORTANT: For ZF IFS axles, ZF recom-
dealer. If corrections are needed, see Group 33 mends that all grease fittings be lubricated once
of the Recreational Vehicle Chassis Workshop a year, preferably before periods of inactivity.
Manual, or take the vehicle to an authorized The wheel hub should be disassembled, in-
Freightliner dealer. spected, and the wheel bearings repacked
every 1,000,000 miles (1 609 000 km).

33/4 Recreational Vehicle Chassis Maintenance Manual, June 2015

Front Axle 33

1. Park the vehicle on a level surface, shut down Workshop Manual and manufacturer literature for
the engine, and set the parking brake. Chock the procedures.
tires.
WARNING
WARNING
Correct wheel-bearing end play is crucial to the
Never work around or under a vehicle that is sup- safe and sound operation of the vehicle. If the end
ported only by a jack. Always support the vehicle play is not correct, the wheel bearings could fail
with safety stands. Jacks can slip, causing the and cause the loss of the wheel and hub assem-
vehicle to fall, which could result in serious injury bly and result in an accident causing property
or death. damage, serious injury, or death. Use a dial indica-
tor to measure the end play.
2. Raise the front of the vehicle and support it with
safety stands. IMPORTANT: Do not measure the wheel bear-
3. Remove the front wheel and tire assemblies. For ing end play with the wheel mounted on the
instructions, see Group 40 of the Recreational hub; you cannot accurately measure or adjust
Vehicle Workshop Manual. bearing end play with the wheel mounted on the
4. Remove the brake drum. For more information, hub. Also, ensure that the brakes are not ap-
see Group 33 of the Recreational Vehicle Work- plied so that that drum and hub can move freely.
shop Manual. 11. Using a dial indicator, measure the end play as
5. Check for loose, damaged, or missing fasteners follows.
and hubcaps. 11.1 Attach the magnetic base of a dial indica-
6. Check for lubricant around the hub cap and tor to the end of the spindle, and place
wheel. If lubricant is present, investigate the the measuring end of the indicator
cause and take corrective action. against the hub cap mounting flange. See
Fig. 9.
7. Check for lubricant around the hub, brake hard-
ware, and brake shoes (if installed). If lubricant is IMPORTANT: Maintain continual pressure on
present, check the oil seal and replace it as nec- the hub until you have taken both the in-
essary. For instructions, see Section 33.03 of board and outboard measurements. If you
the Recreational Vehicle Workshop Manual. release the hub, an accurate measurement
8. Inspect the lubricant for discoloration. Under nor- is not possible.
mal conditions, the lubricant will darken; a white 11.2 To seat the bearings, grip the hub at the
or milky appearance indicates water contamina- three o’clock and nine o’clock positions,
tion. If the lubricant is discolored, service the and push inward while oscillating it ap-
wheel end. See the Recreational Vehicle Work- proximately 45 degrees. Maintain pres-
shop Manual and manufacturer literature for pro- sure on the hub, note the inboard mea-
cedures. surement, and then pull the hub outward
IMPORTANT: Do not mix different types of lubri- while oscillating it as before. Maintain
cants. pressure on the hub, and note the out-
board measurement. See Fig. 10.
9. Inspect the lubricant for the presence of foreign
The end play is the difference between
matter. Use a magnet to detect any metallic ma-
the two measurements. The end play limit
terials present in the lubricant. If the lubricant is
for PreSet hubs is 0.006 inch (0.15 mm);
contaminated, service the hub. See the Recre-
for non-PreSet hubs the acceptable range
ational Vehicle Workshop Manual and manufac-
turer literature for procedures. is 0.001 to 0.005 inch (0.03 to 0.13 mm)
inclusive.
10. Rotate the hub and check for free, smooth, and
quiet rotation. If rotation is hampered, service the If the end play does not exceed the limit
and no other problems were found in the
hub immediately. See the Recreational Vehicle
previous steps, no additional service is

Recreational Vehicle Chassis Maintenance Manual, June 2015 33/5

33 Front Axle

necessary. If the end play exceeds the

limit, service the hub. See the Recre-
33–05 Oil-Filled Hubs Oil Level
ational Vehicle Workshop Manual and Checking
manufacturer literature for procedures.
WARNING
Be careful not to overfill the hubs. Overfilling may
cause oil to be forced out of the hubs and to con-
taminate the brake linings and other brake compo-
nents. This could result in loss of vehicle control
and lead to personal injury and property damage.
1. With the vehicle on a level surface, rotate the
front wheels and allow the oil in the hubs to
settle.
2. Chock the tires.
2 IMPORTANT: The oil level should be at, or no
more than 1/4 inch (6 mm) above the level indi-
cators on the hub caps.
1 3. If necessary, remove the filler caps (in the ends
06/20/2011 f330270
of the hub caps) and add enough oil (80W–90
hypoid gear oil) to bring the oil to the proper
1. Hub Cap Mounting Flange
2. Dial Indicator (with magnetic base)
level.
4. Rotate the wheels, allow the oil to settle, and
Fig. 9, Dial Indicator Setup check the levels again.
A 5. Install the filler caps securely.
6. Remove the chocks from the tires.

33–06 Oil-Filled Hubs Oil

Changing
WARNING
Be careful not to overfill the hubs. Overfilling may
cause oil to be forced out of the hubs and to con-
taminate the brake linings and other brake compo-
nents. This could result in loss of vehicle control
and lead to personal injury and property damage.
A
06/21/2011 f330271
1. With the vehicle on a level surface, rotate the
front wheels so that the front hub drain plugs are
A. Pull and push the hub while oscillating it. positioned downward.
Fig. 10, Measuring End Play 2. Chock the tires.
3. Place suitable containers under the hubs, re-
move the filler plugs (in the ends of the hub
caps) and the drain plugs, and allow the hubs to
drain completely. See Fig. 11.

33/6 Recreational Vehicle Chassis Maintenance Manual, June 2015

Front Axle 33

07/09/2009 f330247b

A. Hub Cavity Full

1. Fill Plug/Magnetic Drain
2. Drain Plug
Fig. 11, Oil-Filled Hub Cap

4. Install the drain plugs and tighten 25 lbf·in (282

N·cm).
5. Add approximately 1 to 1-1/2 pints (0.5 to 0.7 L)
of oil (80W–90 hypoid gear oil) to each hub.
6. Rotate the wheels, allow the oil to settle, and
check the levels.
IMPORTANT: Fill the hubs to the level indicators
on the hub caps, or to no more than 1/4 inch (6
mm) above the indicators. See Fig. 11.
7. Install the filler plugs securely.

Recreational Vehicle Chassis Maintenance Manual, June 2015 33/7

Rear Axle 35
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Axle Breather Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–03
Axle Lubricant Changing and Magnetic Plug Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–02
Axle Lubricant Level Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–01
Oil-Filled Hubs Oil Changing, Tag Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–05
Oil-Filled Hubs Oil Level Checking, Tag Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–04
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–00

Recreational Vehicle Chassis Maintenance Manual, June 2015

Rear Axle 35

35–00 Safety Precautions 4. Check that the lubricant is level with the bottom
of the fill hole. See Fig. 3. If low, check for oil
leaks, and correct as needed. Add oil to the level
Safety Precautions in this section apply to all
of the fill plug, using the lubricant in Table 1 for
procedures within this group. Detroit axles or Table 2 for Meritor axles.

DANGER IMPORTANT: A lubricant level close enough to

be seen or touched is not sufficient. It must be
When working on the vehicle, shut down the en- level with the bottom of the fill hole.
gine, set the parking brake, and chock the tires. 5. Install the oil fill plug and tighten it 30 lbf·ft (41
Before working under the vehicle, always place N·m) for Detroit axles or 35 lbf·ft (47 N·m) for
jack stands under the frame rails to ensure the Meritor axles.
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death.
2
1
35–01 Axle Lubricant Level
Checking

NOTICE
Failure to keep the rear axle filled to the proper A
level with the recommended lubricant can result in
rear axle damage.
NOTE: If the vehicle is exposed to water deep
enough to cover the hubs, disassemble and in- 4
spect them for water damage and/or contamina-
tion. See Group 35 of the Recreational Vehicle
Chassis Workshop Manual for instructions, or
take the vehicle to an authorized Freightliner
dealer.
1. Park the vehicle on a level surface, shut down
the engine, and set the parking brake. Chock the
tires. B
2. If the vehicle has just been driven, allow a few 3
minutes for the lubricant to settle.
3. Clean the fill plug and the area surrounding the 10/17/2012
4 f350574
fill plug on the side of the axle carrier. Remove
the plug. Check lubricant level when the axle is NOTE: Typical engine-rear configuration shown; engine-
front configuration is similar.
cold, or near room temperature. See Fig. 1 and
Fig. 2. A. Rear View
B. Front View
NOTE: Some Meritor axles have a small tapped 1. Axle Housing Breather
and plugged hole located below the housing oil 2. Breather Hose
fill hole. This smaller hole is for the lubricant 3. Oil Fill Plug
temperature sensor only and must not be used 4. Oil Drain Plug
as a fill or level hole. Fig. 1, Component Locations, Detroit Axles

Recreational Vehicle Chassis Maintenance Manual, June 2015 35/1

35 Rear Axle

1 Detroit Drive Axle Lubricants*

IMPORTANT: Lubricant used in Detroit rear axles must

meet Mercedes-Benz specification 235.20 (mineral) or
235.8 (synthetic). Mobil Delvac™ Gear Oil A 80W-90 and
Mobilube™ HD-A Plus 80W-90 meet specification 235.20.
Mobil Delvac 1 Gear Oil 75W-90 and Mobilube 1 SHC
75W-90 meet specification 235.8. For more product
information, see http://bevo.mercedes-benz.com.
SAE
Type Ambient Temperature Viscosity
Grade
Synthetic Oil –40°F (–40°C) and up† 75W–90
* Detroit rear axles do not require the use of friction modifiers.
† There is no upper limit on the ambient temperature, but axle sump tem-
2 perature must never exceed 250°F (121°C).

12/05/2003 f350436 Table 1, Detroit Drive Axle Lubricants

1. Axle Housing Breather
2. Oil Fill Plug Drive Axle Recommended Lubricant, Meritor Axles
Fig. 2, Component Locations, Meritor Axles Lubricant
Recommended SAE
Ambient Temperature
Lubricant Type Viscosity
Grade
A
10°F (–12.2°C) and up* 85W–140
Hypoid Gear Oil –15°F (–26.1°C) and up* 80W–90
API Service
–40°F (–40°C) and up* 75W–90
Classification
GL–5 –40°F (–40°C) to 35°F (2°C) 75W
B –40°F (–40°C) and up* 75W–140
Synthetic Gear –40°F (–40°C) and up* 75W–90
Oil –40°F (–40°C) and up* 75W–140
10/05/2016 f350061a
* There is no upper limit on the ambient temperature, but axle sump tem-
A. Correct (lube level at bottom of fill hole)
perature must never exceed 250°F (121°C).
B. Incorrect (lube level below fill hole)
Table 2, Drive Axle Recommended Lubricant, Meritor
Fig. 3, Checking Axle Lubricant Level Axles

Detroit Drive Axle Lubricants*

35–02 Axle Lubricant Changing
IMPORTANT: Lubricant used in Detroit rear axles must
meet Mercedes-Benz specification 235.20 (mineral) or
and Magnetic Plug
235.8 (synthetic). Mobil Delvac™ Gear Oil A 80W-90 and Cleaning
Mobilube™ HD-A Plus 80W-90 meet specification 235.20.
Mobil Delvac 1 Gear Oil 75W-90 and Mobilube 1 SHC A regular schedule for changing the axle lubricant in
75W-90 meet specification 235.8. For more product a particular vehicle and operation can be accurately
information, see http://bevo.mercedes-benz.com.
determined by analyzing oil samples taken from the
SAE axle at specified intervals or mileages. Lubricant sup-
Type Ambient Temperature Viscosity pliers frequently make their laboratory facilities avail-
Grade able for determining the useful life of their product
Mineral Oil –15°F (–26.1°C) and up† 80W–90 under actual service conditions. The final schedule
that is recommended may, for economic reasons, be

35/2 Recreational Vehicle Chassis Maintenance Manual, June 2015

Rear Axle 35

related to lubricant changes that are governed by be necessary to clean or change the plugs one
climatic conditions and magnetic plug maintenance. or more times between lubrication change inter-
Change lubricant type and viscosity as climatic tem- vals.
peratures demand, regardless of vehicle mileage or
established change schedule. 5. After cleaning the drain plug, install and tighten
the plug 30 lbf·ft (41 N·m) for Detroit axles or 35
The normal operating temperature of compounded lbf·ft (47 N·m) for Meritor axles.
lubricants during the summer season is about 160 to
220°F (71 to 104°C). The chemicals and additives Axle Filling
that give these lubricants increased load carrying ca-
pacity oxidize faster at temperatures above 220°F 1. With the vehicle on a level surface, fill the axle
(104°C), contributing to more rapid lubricant deterio- housings to the bottom of the oil fill hole (in the
ration. For this reason, lubricants of this type that carrier or housing) with recommended lubricant;
operate continuously at high temperatures must be see Table 2. Refer to Table 3 for Detroit drive
changed more frequently. axle lubricant capacities or Table 4 for Meritor
drive axle lubricant capacities.
NOTICE NOTE: Some Meritor axles have a small tapped
and plugged hole located below the housing oil
Failure to change the axle lubricant at more fre-
quent intervals, when adverse operating condi- fill hole. This smaller hole is for the lubricant
tions require, could result in axle damage. temperature sensor only and must not be used
as a fill or level hole.
Axle Draining 2. Install the fill hole plug and tighten it 30 lbf·ft (41
N·m) for Detroit axles or 35 lbf·ft (47 N·m) for
1. Park the vehicle on a level surface, shut down Meritor axles.
the engine, and set the parking brake. Chock the
tires. 3. After filling the carrier and housing assembly with
lubricant, drive the vehicle unloaded for one or
2. Clean the fill plug and the area around it. Re- two miles (two or three kilometers) at speeds not
move the plug from the oil fill hole. See Fig. 1. to exceed 25 mph (40 km/h) to thoroughly circu-
late the lubricant throughout the assembly.
CAUTION
Be careful when draining the axle oil. It may be
very hot, and could cause personal injury if it con- Detroit Drive Axle Lubricant Capacities
tacts the skin. Axle Model* Capacity†: pints (L)
3. Remove the plug at the bottom of the housing ARS–13.0–2 15 (7)
and drain the lubricant while the unit is warm.
ARS–15.0–2 15 (7)
Allow enough time for all the old lubricant to
drain completely. ARS–17.5–2 15 (7)
4. Clean the drain plug. For magnetic drain plugs, a ARS–19.0–2 15 (7)
piece of key stock or any other convenient steel ARS–20.0–2 15 (7)
slug may be used to short the two magnetic
ARS–21.0–2 15 (7)
poles and divert the magnetic field.
ARS–21.0–4 23 (11)
NOTE: Meritor recommends using magnetic
plugs with elements having a minimum pickup ARS–23.0–4 23 (11)
capacity of two pounds (one kilogram) of low- * Model code may have a "D" in the prefix (for example, DA–RS–13.0–2).

carbon steel in plate or bar form. Magnets will † Quantities listed are approximate and include 1 pint (0.5 liter) for each
wheel end and with the drive pinion at 3 degrees.
rapidly lose effectiveness as collected material
bridges the gap between the two poles. Clean Table 3, Detroit Drive Axle Lubricant Capacities
or change the plugs before this occurs. It may

Recreational Vehicle Chassis Maintenance Manual, June 2015 35/3

35 Rear Axle

Meritor Drive Axle Lubricant Capacities 35–04 Oil-Filled Hubs Oil Level
Axle Model Capacity*: pints (L) Checking, Tag Axle
MS–10–113D 14 (6.6)
MS–12–113D 15 (7.1)
WARNING
RS–13–120 18.4 (8.7)
RS–15–120 14.3 (6.8)
Be careful not to overfill the hubs. Overfilling may
cause oil to be forced out of the hubs and to con-
RS–17–145 33.6 (15.9) taminate the brake linings and other brake compo-
RS–17–144 32.3 (15.3) nents. This could result in loss of vehicle control
and lead to personal injury and property damage.
RS–19–144 32.3 (15.3)
RS–19–145 33.2 (15.7)
1. With the vehicle on a level surface, remove the
hub cap (also referred to as a beauty ring). See
RS–21–145 32.3 (15.3) Fig. 4.
RS–21–160 39.5 (18.7)
RS–21–230 38.9 (18.4)
RS–23–160 39.5 (18.7) 2
RS–23–161 39.5 (18.7) 1
RS–23–186 47.3 (22.4)
RS–23–240 37.4 (17.7)
RS–26–185 38.0 (18.0)
RS–30–185 38.0 (18.0)
* Quantities listed are approximate and include 1 pint (0.5 liter) for each
wheel end and with the drive pinion at 3 degrees.
Table 4, Meritor Drive Axle Lubricant Capacities

07/28/2010 f400295
35–03 Axle Breather Checking
1. Cap Head
NOTE: Detroit axles have a breather hose 2. Hub Cap (Beauty Ring)
wrapped around the housing breather. The Fig. 4, Rear Axle Hub Cap Assembly
breather hose length should not be lower than
approximately 1 inch below the axle housing 2. Rotate the rear wheels and allow the oil in the
weld seam. hubs to settle.
The axle housing breather must remain clean. See 3. Chock the tires.
Fig. 1 and Fig. 2. When the axle lubricant level is IMPORTANT: The oil level should be at, or no
checked, check that the axle breather is open. Check more than 1/4 inch (6 mm) above the level indi-
more often under poor operating conditions. If the
cators on the hub caps.
breather is plugged, clean it or replace it as needed.
4. If necessary, remove the filler caps (in the ends
of the hub caps) and add enough oil (80W–90
hypoid gear oil) to bring the oil to the proper
level.
5. Rotate the wheels, allow the oil to settle, and
check the levels again.
6. Install the filler caps securely.

35/4 Recreational Vehicle Chassis Maintenance Manual, June 2015

Rear Axle 35

NOTICE 2
Do not overtighten the cap head. Too much force
will strip the screw.
7. Install the hub cap and tighten the cap head just
until snug.

35–05 Oil-Filled Hubs Oil

1
Changing, Tag Axle
WARNING A

Be careful not to overfill the hubs. Overfilling may

cause oil to be forced out of the hubs and to con- 07/09/2009 f330247b
taminate the brake linings and other brake compo- A. Hub Cavity Full
nents. This could result in loss of vehicle control
1. Fill Plug/Magnetic Drain
and lead to personal injury and property damage. 2. Drain Plug
1. With the vehicle on a level surface, remove the
hub cap (also referred to as a beauty ring). Fig. 5, Oil-Filled Hub Cap

2. Rotate the rear wheels so that the rear hub drain

plugs are positioned downward.
3. Chock the tires.
4. Place suitable containers under the hubs, re-
move the filler plugs (in the ends of the hub
caps) and the drain plugs, and allow the hubs to
drain completely. See Fig. 5.
5. Install the drain plugs and tighten securely.
6. Add approximately 1 to 1-1/2 pints (0.5 to 0.7 L)
of oil (80W–90 hypoid gear oil) to each hub.
IMPORTANT: Fill the hubs to the level indicators
on the hub caps, or to no more than 1/4 inch (6
mm) above the indicators. See Fig. 5.
7. Rotate the wheels, allow the oil to settle, and
check the levels.
8. Install the filler plugs securely.

NOTICE
Do not overtighten the cap head. Too much force
will strip the screw.
9. Install the hub cap and tighten the cap head just
until snug.

Recreational Vehicle Chassis Maintenance Manual, June 2015 35/5

Wheels and Tires 40
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Wheel Cleaning and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–02
Wheel Nut Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–01

Recreational Vehicle Chassis Maintenance Manual, May 2011

Wheels and Tires 40

40–01 Wheel Nut Checking A B

IMPORTANT: In addition to the maintenance 2 1

interval in this manual, check the wheel nut
4 5 3 6
torque the first 50 to 100 miles (80 to 160 km)
of operation after a wheel has been removed
and installed. 6 3 5 4
1 2
NOTE: On each wheel stud, the end that faces
away from the vehicle is stamped with an "L" or 08/20/96 f400119
an "R," depending on which side of the vehicle A. Front and Inner Rear Dual
the stud is installed. Studs stamped with an "L" B. Outer Rear Dual
are left-hand threaded and are installed on the
driver’s side of the vehicle. Studs stamped with Fig. 1, Wheel Nut Tightening Sequence (6-stud hubs)
an "R" are right-hand threaded and are installed
on the passenger’s side of the vehicle. A B
When checking wheel nuts on a dual disc assembly, 2 1
remove one outer nut at a time, tighten the inner nut, 4 5 3 6
then reinstall the outer nut. Repeat this procedure for
all of the inner wheel nuts in the sequence shown in
Fig. 1, Fig. 2, or Fig. 3. Then, tighten all of the outer 8 7 7 8
wheel nuts in the same sequence.

CAUTION 6 3 5 4
1 2
Too little wheel nut torque can cause wheel
shimmy, resulting in wheel damage, stud break- 06/23/2000 f400159
age, and extreme tire tread wear. Too much wheel A. Front and Inner Rear Dual
nut torque can break studs, damage threads, and B. Outer Rear Dual
crack discs in the stud hole area.
Fig. 2, Wheel Nut Tightening Sequence (8-stud hubs)
Tighten the wheel nuts.
• On 6-stud, stud-pilot hubs, tighten the wheel A B
nuts 450 to 500 lbf·ft (610 to 678 N·m). See
Fig. 1 for the tightening sequence. 2 1
9 7 10 8
• On 8-stud or 10-stud, hub-pilot hubs with
20-mm studs, tighten the wheel nuts 280 to 310 4 5 3 6
lbf·ft (380 to 420 N·m). See Fig. 2 or Fig. 3 for
the tightening sequence.
6 3 5 4
• On 8-stud or 10-stud, hub-pilot hubs with
22-mm studs, tighten the wheel nuts 450 to 500 8 10 7 9
lbf·ft (610 to 678 N·m). See Fig. 2 or Fig. 3 for 1 2
the tightening sequence.
NOTE: Wheel nuts for 20-mm stud hubs require 09/28/98 f400142
a 1- 3/16-inch (30-mm) socket. Wheel nuts for A. Front and Inner Rear Dual
22-mm stud hubs require a 1-5/16-inch (33-mm) B. Outer Rear Dual
socket.
Fig. 3, Wheel Nut Tightening Sequence (10-stud hubs)

Recreational Vehicle Chassis Maintenance Manual, May 2011 40/1

40 Wheels and Tires

40–02 Wheel Cleaning and

Polishing
Accuride® Machined and
Polished Aluminum Wheels
IMPORTANT: Do not scrub the wheels before
rinsing off particles with high-pressure water.
Rubbing debris against the surface of the wheel
can result in scratches. Synthetic cleaning pads
and wire brushes should not be used to clean
the wheels.
Do not use strong detergents, alkaline, or acidic
cleaners to clean Accuride aluminum wheels.
These solutions can etch the surface of the alu-
minum and leave dull areas. Do not use pol-
ishes or wax on Accuride ACCU-SHIELD alumi-
num wheels.
1. Rinse the wheel with high-pressure water to re-
move debris.
2. Use a 100% cotton cloth dipped in a mild soap
solution to help remove built up dirt and grease.
Dish soap or automotive car wash soap are rec-
ommended.
3. Rinse the remaining soap residue from the
wheel. Do not allow soap residue to dry on the
surface of the wheel.
4. Dry the wheel thoroughly with a 100% cotton
cloth.
5. Commercial bug/tar/grime cleaners may be used
to remove stuck-on particles from the wheel. It is
recommended that the cleaner be tested in an
inconspicuous area for discoloration before treat-
ing the wheel.
6. Do not use strong solvents to remove grease or
grime from the surface of the wheel. Damage to
the wheel surface finish might occur.
7. Do not use polishes or wax on ACCU-SHIELD
aluminum wheels. The finish will maintain the
bright and shiny surface for years to come with-
out the need for special polishes.

40/2 Recreational Vehicle Chassis Maintenance Manual, May 2011

Driveline 41
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Driveline Inspection and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–01
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–00

Recreational Vehicle Chassis Maintenance Manual, June 2015

Driveline 41

41–00 Safety Precautions yoke plug and knocking it out; check the drive-
shaft for proper length.
Safety Precautions in this section apply to all
procedures within this group. U-Joint Lubrication
1. Wipe all old grease and dirt from each U-joint
DANGER grease fitting.
2. Use a hand-type grease gun, or a high-pressure
When working on the vehicle, shut down the en- gun with a low-pressure adaptor, to lubricate the
gine, set the parking brake, and chock the tires. U-joints. See Fig. 1.
Before working under the vehicle, always place
jack stands under the frame rails to ensure the 5
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death.

41–01 Driveline Inspection and

Lubrication 1
3
4
7
Inspection 2 3

Before lubricating the driveline U-joints and slip-

joints, make the following checks. 6
1. Check that the yoke-strap capscrews are tight-
ened 50 to 60 lbf·ft (68 to 81 N·m).
8
NOTICE 3 1
Do not overtighten the yoke-strap capscrews, due A
to the extreme load occurring at high-speed rota-
tion. A loose or broken capscrew at any point in
the driveline weakens the driveline connection, 10/07/2016 f410050a
which could eventually result in serious vehicle
damage. A. After grease appears, cover the pressure-relief hole
while continuing to lubricate.
2. Check the slip-joints for spline wear by trying to 1. Slip-Joint Grease 5. Yoke Plug Pressure-
bend the sleeve-yoke and splined shaft back and Fitting (with grease Relief-Hole
forth. If looseness is greater than 0.007 inch gun attached) 6. Slip-Joint Seal
(0.18 mm), replace both the sleeve-yoke and the 2. Yoke Plug 7. Full-Round Yoke
splined shaft. 3. Grease 8. U-Joint Grease Fitting
4. Half-Round Yoke
3. Check the driveshaft for missing balance
weights, and for debris buildup. Remove any Fig. 1, Slip-Joint and U-Joint Lubricating
buildup. If any balance weights are missing, re-
move the driveshaft and have it balanced. For NOTE: If a low-pressure adaptor is not used
instructions, see Group 41 of the vehicle Work- with the high-pressure gun, the U-joints may not
shop Manual, or take the vehicle to an autho- receive enough lubricant.
rized Freightliner dealer.
3. Using lithium 12-hydroxy stearate grease (NLGI
4. Check that the yoke plug is not loose or missing. grade 1 or 2, with EP additives), lubricate until
Replace the yoke plug if needed. If the yoke plug new grease can be seen at all four U-joint seals.
is missing, the splined shaft may be hitting the

Recreational Vehicle Chassis Maintenance Manual, June 2015 41/1

41 Driveline

NOTICE
Fresh lubricant must be seen escaping from all
four of the bearing cup seals of each U-joint. If
not, the U-joint may fail prematurely.
4. If the bearing will not take grease, replace the
U-joint assembly. For instructions, see Group 41
of the vehicle Workshop Manual, or take the ve-
hicle to an authorized Freightliner dealer.
5. Check the old grease. If it appears rusty, gritty, or
burned, replace the U-joint assembly. For instruc-
tions, see Group 41 of the vehicle Workshop
Manual, or take the vehicle to an authorized
Freightliner dealer.
6. Wipe any excess grease from the seals and
grease fittings.

Slip-Joint Spline Lubrication

1. Wipe all old grease and dirt from the slip-joint
grease fitting.
2. Use a hand-type grease gun or a high-pressure
gun with a low-pressure adaptor, to lubricate the
slip-joint. Using lithium 12-hydroxy stearate
grease (NLGI grade 1 or 2, with EP additives),
lubricate until fresh grease appears at the
pressure-relief hole in the yoke plug. Then cover
the relief hole with your finger, as shown in
Fig. 1, while continuing to lubricate until fresh
grease appears at the slip-joint seal. This en-
sures complete lubrication of the splines.
3. Wipe any excess grease from the pressure-relief
hole, slip-joint seal, and grease fitting.

41/2 Recreational Vehicle Chassis Maintenance Manual, June 2015

Brakes 42
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Air Dryer Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–02
Air Dryer Desiccant and Coalescent Filter Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–03
Bendix Automatic Drain Valve Operating and Leakage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–14
Bendix Hydro-Max® Brake System Inspecting (front-engine diesel chassis) . . . . . . . . . . . . . . . . . . . . . . . 42–07
Brake Caliper Slide Pin Lubricating, Bosch Brakes (front-engine diesel chassis) . . . . . . . . . . . . . . . . . . . . 42–08
Brake Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–11
Brake Lines Checking, Hydraulic Disc or Air Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–09
Brake Lining Wear Checking, Hydraulic Disc Brakes (front-engine diesel
chassis)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–10
Brake System Valves Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–01
Camshaft Bracket Bushing Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–04
Foot Brake Valve Actuator Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–06
Meritor Roller Pin Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–12
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–00
Slack Adjuster Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–05
Versajust Slack Adjuster Inspection and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–13

Recreational Vehicle Chassis Maintenance Manual, July 2018

Brakes 42

42–00 Safety Precautions Because no two vehicles operate under identical

conditions, maintenance and maintenance intervals
will vary. Experience is a valuable guide in determin-
Safety Precautions in this section apply to all
ing the best maintenance interval for any one particu-
procedures within this group. lar operation.
Every 12 months:
DANGER
1. Check for moisture in the air brake system by
When working on the vehicle, shut down the en- opening reservoir drain valves and checking for
gine, set the parking brake, and chock the tires. presence of water. If moisture is present, the
Before working under the vehicle, always place desiccant cartridge may require replacement;
jack stands under the frame rails to ensure the however, the following conditions can also cause
vehicle cannot drop. Failure to follow these steps water accumulation and should be considered
could result in serious personal injury or death. before replacing the desiccant:
• An outside air source has been used to
42–01 Brake System Valves charge the system. This air did not pass
through the drying bed.
Inspecting • Air usage is exceptionally high and not nor-
1. Clean the valves exterior and inspect them for mal. This may be due to high air system
corrosion and damage. leakage.
2. Inspect the air lines connected to the valves for • In areas where more than a 30-degree
signs of wear or damage. Replace the lines as range of temperature occurs in one day,
needed. small amounts of water can temporarily
accumulate in the air brake system due to
3. Check the valves for leakage. condensation. Under these conditions, the
3.1 Apply the service brakes and hold them presence of small amounts of moisture is
on a full line pressure of at least 80 psi normal.
(552 kPa). NOTE: A small amount of oil in the system is
3.2 Check the air line fittings for leaks; tighten normal and should not be considered as a rea-
or replace the fittings as needed. son to replace the desiccant cartridge. Some oil
3.3 Coat the exhaust port and body of the at the dryer exhaust is normal.
valves with soapy water, and check for 2. Visually check for physical damage, such as
leakage. Leakage is excessive if it pro- chaffed or broken air and electrical lines and bro-
duces a 1-inch (25-mm) bubble within 5 ken or missing parts.
seconds.
3. Check the mounting bolts for tightness. See
If a brake valve does not function as de- Table 1 for torque values.
scribed above, or if leakage is excessive,
replace it with a new or remanufactured Torque Values
unit. Repeat the leakage checks before
Torque:
placing the vehicle in service. Vendor Size
lbf·ft (N·m)
Grade 5, 3/8–16 28 (38)
42–02 Air Dryer Checking Bendix
Grade 5, 5/8–11 135 (183)
IMPORTANT: Review the warranty policy before Haldex 1/2–13 45 to 55 (61 to 75)
performing any intrusive maintenance proce- Table 1, Torque Values
dures. An extended warranty may be voided if 4. Perform the operational and leakage tests listed
intrusive maintenance is performed during this below.
period.

Recreational Vehicle Chassis Maintenance Manual, July 2018 42/1

42 Brakes

Operational and Leakage Tests and heater assembly to below 40°F

(4°C). Using an ohmmeter, check the re-
1. Check all lines and fittings leading to and from sistance between the electrical pins in the
the air dryer for leakage and integrity. Repair any air dryer connector half. The resistance
leaks found. should be 1.5 to 3.0 ohms for the 12-volt
2. Build system pressure to governor cutout and heater assembly and 6.0 to 9.0 ohms for
note that the dryer purges with an audible es- the 24-volt heater assembly.
cape of air. Watch the system pressure and note NOTE: Some models of the AD–9 may
the pressure fall-off for a 10-minute period. If the have a resistance reading of 1.0 to 2.5
pressure drop exceeds 1 psi/minute from either ohms.
service reservoir, inspect the vehicle air systems
Warm the thermostat and heater assem-
for sources of leakage and repair them. Refer to
bly to approximately 90°F (32°C) and
troubleshooting information in Bendix or Haldex
again check the resistance. The resis-
service literature.
tance should exceed 1000 ohms. If the
3. Check for excessive leakage around the purge resistance values obtained are within the
valve with the compressor in the loaded mode stated limits, the thermostat and heater
(compressing air). Apply a soap solution to the assembly is operating properly. If the re-
purge valve exhaust port and observe that leak- sistance values obtained are outside the
age does not exceed a 1-inch (25-mm) bubble in stated limits, replace the heater and ther-
1 second. If the leakage exceeds the maximum mostat assembly.
specified, refer to troubleshooting information in
the Bendix or Haldex service literature.
42–03 Air Dryer Desiccant and
4. Build system pressure to governor cutout and
note that the dryer purges with an audible es- Coalescent Filter
cape of air. Fan the service brakes to reduce
system air pressure to governor cut-in. Note that
Replacing
the system once again builds to full pressure and
NOTE: Desiccant change intervals may vary
is followed by a dryer purge. If the system does
not follow this pattern, refer to troubleshooting from vehicle to vehicle. Typical desiccant car-
information in the Bendix or Haldex service litera- tridge life is three years. However, if experience
ture. has shown that extended or shortened life has
resulted on a particular installation, then the in-
5. Check the operation of the end cover heater and
terval can be increased or decreased accord-
thermostat assembly during cold weather opera-
tion as follows: ingly.
5.1 Electric Power to the Dryer: With the igni-
tion in the ON position, check for voltage
Bendix AD-9
to the heater and thermostat assembly 1. Park the vehicle on a level surface, shut down
using a voltmeter or testlight. Unplug the the engine, and set the parking brake. Chock the
electrical connector at the air dryer and tires.
place the test leads on each of the con- 2. Completely drain all air reservoirs. Air pressure
nections of the female connector on the gauges should read 0 psi (0 kPa).
vehicle power lead. If there is no voltage,
look for a blown fuse, broken wires, or 3. Loosen the desiccant cartridge with a strap
corrosion in the vehicle wiring harness. wrench at the base of the cartridge. Spin off the
Check to see if a good ground path ex- cartridge and discard it.
ists. 4. Remove the O-ring from the threaded neck and
5.2 Thermostat and Heater Assembly Opera- discard it.
tion: These tests are not possible except 5. Remove the coalescent filter and discard it.
in cold weather operation. Turn off the
ignition switch and cool the thermostat

42/2 Recreational Vehicle Chassis Maintenance Manual, July 2018

Brakes 42

IMPORTANT: Lubricate the new O-rings prior to 5. Using a clean rag, wipe clean the inside of the
installation. end cover. Clean the cartridge bolt bore in the
end cover, and the sealing surfaces for the large-
6. Install the new small O-ring in the groove on the and small-diameter desiccant cartridge sealing
bottom of the new coalescent filter. rings.
7. Insert the coalescent filter with the O-ring end 6. Inspect the end cover for physical damage, then
going into the air dryer opening first. The end of inspect all air line fittings for corrosion; replace
the filter with the "X" will then be facing out. as necessary.
8. Install the other new O-ring over the threaded 7. Clean and inspect the bolt, paying attention to
neck of the desiccant cartridge. the threads and O-ring grooves.
9. Screw on the desiccant cartridge until resistance
IMPORTANT: Use only the grease supplied with
is detected. Then, tighten the cartridge 1/4 to 3/4
of a turn by hand. Bendix replacement kits.
10. Before placing the vehicle in service, perform the 8. Lubricate the O-rings, bolt O-ring grooves, seal-
test below. ing rings, and cartridge grooves. Lubricate the
end cover bore for the bolt.
10.1 Start the engine and build air pressure to
120 psi (827 kPa). 9. Install both O-rings on the cartridge bolt, then,
using a twisting motion, insert the assembled
10.2 Listen for the purge valve to open and desiccant cartridge bolt in the end cover.
release air. A large volume of air will be
expelled, followed by a slow flow of air 10. Install the desiccant cartridge on the end cover,
lasting approximately 30 seconds. making sure the cartridge is properly seated and
flush on the end cover.
10.3 Shut down the engine.
NOTE: It may be necessary to rotate the car-
10.4 Perform the inspections in Maintenance tridge slightly until the anti-rotation lugs are
Operation 42–02. properly aligned and allow the cartridge to rest
flush against the end cover.
Bendix AD-IP
11. Using a wrench or socket, tighten the desiccant
1. Park the vehicle on a level surface, shut down cartridge bolt 50 lbf·ft (68 N·m). Do not over-
the engine, and set the parking brake. Chock the torque.
tires.
12. Before placing the vehicle in service, perform the
2. Using a wrench or a socket, loosen the desiccant test below.
cartridge bolt. Then separate the desiccant car-
tridge from the end cover. 12.1 Close all reservoir drain cocks.

3. Pull the cartridge bolt out of the cover and re- 12.2 Build system pressure to governor cut-
move the cartridge. out, and note that the AD-IP air dryer
purges with an audible escape of air.
WARNING 12.3 Fan the service brakes to reduce system
air pressure to governor cut-in. Note that
Do not attempt to disassemble the desiccant car- the system once again builds to full pres-
tridge assembly. Parts for the assembly are not sure and is followed by a purge at the
available and the cartridge contains a 150 lb AD-IP air dryer exhaust.
spring that cannot be mechanically caged. Disas- 12.4 Check for excessive leakage around the
sembly could release the spring, resulting in per- head of the desiccant cartridge where it
sonal injury. contacts the end cover. With the com-
4. Remove and discard both O-rings from the car- pressor in loaded mode (compressing
tridge bolt. air), apply a soapy solution to these
areas, and observe that any leakage
does not exceed a 1-inch bubble in 1

Recreational Vehicle Chassis Maintenance Manual, July 2018 42/3

42 Brakes

second. If leakage exceeds this measure,

remove and re-install the desiccant
cartridge.
3
Haldex PURest1
NOTE: The PURest cartridge contains both the
desiccant and filter in one piece.
1. Park the vehicle on a level surface, shut down
the engine, and set the parking brake. Chock the
tires.
2. Remove the four mounting bolts and discard.
See Fig. 1. Lift the canister about 1/2 inch and 2
remove.
3. Place the assembly upside-down as shown in
Fig. 2. Press the cartridge down to compress the
rubber spring then rotate counterclockwise 45
degrees to release the cartridge. The cartridge
itself contains no hazardous material, but there 1
may be a small amount of oil from the
compressor.
4. Clean the inside of the canister and aluminum
housing.
5. Remove the cartridge O-ring and discard.
6. Remove the new cartridge from the kit and make
certain the rubber spring is attached. See Fig. 3.
7. Install the new cartridge into the canister. Align 01/07/2011 f422526
the slots on the cartridge with the dimplets inside
1. O-ring 3. Mounting Bolts
the canister. Press the cartridge into the canister 2. Cartridge
and rotate clockwise 45 degrees to engage the
cartridge, as shown in Fig. 4. Fig. 1, PURest Air Dryer Assembly
8. Place a new O-ring on the aluminum housing. 10.3 Restart the engine and build-up pressure
9. Place the cartridge assembly on the air dryer to cut-out pressure. At cut-out pressure,
housing and install four new mounting bolts. Use the air dryer purge valve opens and im-
an alternating diagonal pattern and tighten the mediately expels a large volume of air,
bolts 35 to 40 lbf·ft (47 to 54 N·m). followed by a slow flow of air lasting ap-
proximately 30 seconds.
10. Before placing the vehicle in service, perform the
test below.
WABCO System Saver 1200
10.1 Start the engine and build air pressure to
100 psi (690 kPa) and shut-off the en- Plus
gine.
10.2 Check for air leaks at the inlet, outlet, and NOTICE
canister assembly. Correct any leakage
problem. The WABCO System Saver air dryers can use ei-
ther a standard or oil coalescing desiccant car-
1Information in this section is provided by Haldex and is used with permis- tridge. When replacing the desiccant cartridge, it
sion. is very important to use the same type of car-

42/4 Recreational Vehicle Chassis Maintenance Manual, July 2018

Brakes 42

A B
B

01/10/2011 f422527

A. Canister/cartridge assembly shown upside-down.

B. Rotate the cartridge counterclockwise 45 degrees to
release it from the canister.
Fig. 2, Releasing the Cartridge

B A B

01/10/2011 f422529

A. Install the new cartridge into the canister.

B. Press the cartridge into the canister and rotate
clockwise 45 degrees to engage the cartridge.
Fig. 4, Cartridge Rotation and Engagement

this may result in contamination and malfunction-

ing of downstream air system components.
Refer to Fig. 5 for cartridge replacement.
1. Drain the air system.
01/07/2011 f422528
2. Using a strap wrench, turn the desiccant car-
tridge counterclockwise and remove it.
Fig. 3, New Cartridge with Rubber Spring
3. Remove and discard the O-ring.
tridge that was originally installed on the dryer. Oil
coalescing cartridges can be used in any applica- 4. Clean the top surface of the dryer base with a
tion, but require more frequent service intervals commercial cleaning solvent.
(every 1 to 2 years instead of every 2 to 3 years IMPORTANT: If the air dryer base is damaged,
for a standard cartridge). Do not replace an oil co- preventing a tight seal, replace the air dryer.
alescing cartridge with a standard cartridge, as

Recreational Vehicle Chassis Maintenance Manual, July 2018 42/5

42 Brakes

3
2
3
2

1 A
10/07/2016 f420011a
A. Grease Exit
1. Brake Chamber
2. Slack Adjuster
3. Non-Pressure-Relief Grease Fitting
10/07/2016 f421292
Fig. 6, Camshaft Bracket Bushing Lubrication
1. Seal 3. Air Dryer Base
2. O-Ring lubrication-interval chassis grease. Grease them only
when the camshaft is disassembled for servicing.
Fig. 5, Desiccant Cartridge Replacement

5. Using a multipurpose, high-temperature grease 42–05 Slack Adjuster

that resists water, steam, and alkali, lightly coat
the surfaces of the new O-ring and the dryer Lubricating
base. Install the O-ring.
6. Thread the desiccant cartridge onto the dryer IMPORTANT: Perform Maintenance Operation
base (turn clockwise). When the seal contacts 42–11 before lubricating the slack adjusters.
the base, tighten the cartridge one complete turn Automatic slack adjusters must be lubricated periodi-
more. Do not overtighten. cally to ensure proper brake operation.

42–04 Camshaft Bracket WARNING

Bushing Lubricating Failure to lubricate slack adjusters could lead to
dragging brakes or a brake failure, resulting in
Pump grease into the camshaft bracket bushing until property damage, personal injury, or death.
it appears at the slack adjuster end of the bracket.
See Fig. 6. Haldex
Use an NLGI Grade 1 or Grade 2 multipurpose chas-
sis grease. If grease leaks out from under the cam
head, the camshaft bracket grease seal is worn or
NOTICE
damaged. For grease seal replacement instructions, Do not use moly-disulfide-loaded grease or oil.
see Group 42 of the Recreational Vehicle Chassis Both the life and reliability of the slack adjuster
Workshop Manual, or take the vehicle to an autho- will be reduced if this type of grease is used.
rized Freightliner dealer.
Lubricate a Haldex automatic slack adjuster at the
Camshaft brackets without grease fittings are fitted grease fitting with any extreme-pressure NLGI Grade
with special seals and packed with extended- 1 or Grade 2 grease if the operating temperature is

42/6 Recreational Vehicle Chassis Maintenance Manual, July 2018

Brakes 42

–20°F (–29°C) and above. If the operating tempera- 1

ture is below –20°F (–29°C), use a low-temperature
extreme-pressure grease.

Meritor 3
Lubricate the slack adjuster at the grease fitting until 2
2 3
grease is forced past the pressure-relief capscrew or
past the gear splines around the inboard snap ring. 4
Use high-temperature, NLGI Grade 1 waterproof
grease. See Fig. 7. 5

2
6
7
7
3 06/17/2010 f430511

1. Yoke 5. Boot
4
2. Yoke Pin 6. Lube Fitting
3. Link Pin 7. Worm Gear
4. Link
5
Fig. 8, Bendix Automatic Slack Adjuster
7
2. Use light oil to lubricate the brake pedal roller
6 f420012a and pivot pin.
10/20/93
1. Brake Chamber 5. Pull-Pawl Seal 3. Check the brake plunger boot for cracks, holes,
2. Clevis 6. Manual Adjusting Nut or deterioration. Replace it if necessary.
3. Actuator Rod 7. Grease Fitting (or
4. Boot Lube Plug) 4. Lift the edge of the brake plunger boot and
check the plunger for existing lubrication.
Fig. 7, Meritor Automatic Slack Adjuster (other slack
adjustors are similar) 4.1 If the plunger is dry, remove it by remov-
ing the brake pedal and brake plunger
Bendix boot. Lubricate the plunger and the inside
surface of the boot with barium grease
Using a quality multipurpose chassis lubricant, NLGI (p/n BW 246671) or Pennzoil Adhezoplex
Grade 2, lubricate the automatic slack adjuster EP2. Install the plunger, boot, and the
through the lube fitting. See Fig. 8. Lubricate the brake pedal.
slack adjuster until clean lubricant flows from the
grease relief opening in the boot. IMPORTANT: Use only these approved lubri-
cants.
4.2 If the plunger has grease on it, lift the
42–06 Foot Brake Valve edge of the brake plunger boot enough to
Actuator Lubricating apply 2 to 4 drops of light oil around the
brake plunger, where it slides into the
1. Clean any dirt, gravel, and other foreign material brake base bracket. Install the plunger
from the base of the brake pedal, the plunger boot around the brake base bracket.
boot, and the brake base bracket.

Recreational Vehicle Chassis Maintenance Manual, July 2018 42/7

42 Brakes

42–07 Bendix Hydro-Max® 4. Check the electrical connections and harnesses.

Make sure the connectors are fully seated and
Brake System Inspecting the harnesses are not chafed or cut. Repair or
replace any damaged harness. Disconnect any
(front-engine diesel loose connectors and inspect the terminals for
chassis) corrosion. If corrosion is present, replace the ter-
minals. If corrosion is not present, reconnect the
1. Check the fluid level in the hydraulic brake fluid connector.
reservoir. If needed, fill the reservoir up to the 5. Check the fuse for the hydraulic brake booster
ridge that surrounds the reservoir. See Fig. 9. pump, as follows.
Use only heavy-duty brake fluid, DOT 3.
5.1 Open the cover to the main power distri-
bution module (PDM).
B
5.2 Pull the fuse in position F6 for the Hydro-
Max relay.
5.3 Inspect the relay to make sure the fuse is
not damaged. If the fuse is damaged, in-
stall a new fuse. If the fuse is not dam-
A aged, install the fuse in position F6.
5.4 Close the PDM cover.
6. Check the operation of the Hydro-Max brake
booster, as follows.
6.1 With the ignition off, depress the brake
pedal and listen for the back-up motor to
engage. Also note that the pedal force
relieves; the pedal should depress easily.
6.2 With the ignition on, engine running, park-
ing brake released, ensure that the
BRAKE warning indicator light is not on.
This is a dual indicator and indicates that
the parking brake is set, and warns if
there is a hydro-max failure other than
07/31/2015 f460513b
loss of back-up motor power.

A. Open caps and check fluid level.

B. Fill to this level. 42–08 Brake Caliper Slide Pin
Fig. 9, Hydraulic Brake Fluid Reservoir Lubricating, Bosch
2. Check all hydraulic lines and fittings for damage, Brakes (front-engine
leakage, or looseness. diesel chassis)
Replace damaged or leaking components, and
tighten loose fittings. NOTE: There is no set maintenance interval for
3. Check the brake module for leaks. If leaks are
lubricating pin-slide hydraulic disc brake cali-
found, repair or replace the brake module. See pers.
Group 42 of the Recreational Vehicle Chassis Apply 1/8 oz (3.5 g) Aeroshell grade 5 grease to
Workshop Manual for replacement instructions, each of the two guide pin and guide pin bore sets.
or take the vehicle to an authorized Freightliner See the Bosch Pin Slide Disc Brakes Service Manual
Chassis dealer. for additional information.

42/8 Recreational Vehicle Chassis Maintenance Manual, July 2018

Brakes 42

IMPORTANT: The later ZOH-T caliper has im-

portant differences from the early ZOPS caliper.
ZOPS calipers (since 1998) and ZOH-T calipers
(since 2002) use different slide pins and bolts.
See Fig. 10 and Fig. 11. The later trailing pin is 3
identified by notches and has a rubber bushing. 1 2
Flange-head instead of hexhead bolts are used 3
with the later caliper. The later bolts have a fine
thread rather than a coarse thread pitch, are
longer, differently colored, and are tightened to a
higher torque specification. Use only the ZOH-T 06/20/2002 f422358
bolts to assemble a ZOH-T caliper. The ZOPS 1. Hexhead Bolt 3. Slide Pin
caliper bolts have a different thread pitch and 2. Blue Patch
will not assemble correctly in a ZOH-T caliper
mounting. Also, the ZOH-T bolts will not as- Fig. 11, ZOPS Slide Pins and Bolts
semble correctly in a ZOPS caliper. Do not in- notches for identification. With ZOH-T calipers,
terchange parts. It is permissible to use both install the solid pin (no bushing) only in the an-
ZOH-T pins and ZOH-T bolts in a ZOPS anchor chor plate leading hole position. Install the pin
plate, but they must be replaced as sets. Both with the rubber bushing and notches only in the
the pins and the bolts must be changed. anchor plate trailing hole position. Tighten the
leading-side pin first, then tighten the trailing-
side pin.
Tighten ZOH-T bolts 93 to 107 lbf·ft (126 to 145
N·m).
2 Tighten ZOPS bolts 70 to 80 lbf·ft (95 to 108 N·m).
1 4
3
42–09 Brake Lines Checking,
Hydraulic Disc or Air
06/20/2002 f422357
Brakes
1. Flange-Head Bolt 3. Trailing Pin Check all hydraulic/air lines and fittings for damage,
2. Leading Pin 4. Rubber Bushing leakage, or looseness.
Fig. 10, ZOH-T Slide Pins and Bolts Replace damaged or leaking components, and
tighten loose fittings.
DANGER
The correct pins, bolts, and bolt torque must be
42–10 Brake Lining Wear
used. If not, brake function could be impaired and Checking, Hydraulic
lead to loss of control of the vehicle, which could
result in personal injury, death, or property dam-
Disc Brakes (front-
age. engine diesel chassis)
IMPORTANT: The ZOH-T caliper assembly is Before checking lining wear with the wheel removed,
similar in appearance to the existing ZOPS cali- review the following brake lining exposure warnings.
per. The only obvious difference is that one of
the anchor plate slide pins (trailing side) has

Recreational Vehicle Chassis Maintenance Manual, July 2018 42/9

42 Brakes

2. Put the vehicle in the lowest gear and gently at-

WARNING tempt to move it forward. The vehicle should not
move. If the vehicle moves, the parking brakes
Breathing brake lining dust (asbestos or non- are not operating correctly and must be repaired
asbestos) could cause lung cancer or lung dis- before the vehicle is returned to service. See
ease. Unless exposure can be reduced below legal Group 42 of the Recreational Vehicle Chassis
limits, wear an air purifying respirator approved Workshop Manual for repair procedures, or take
by MSHA or NIOSH at all times when servicing the the vehicle to an authorized Freightliner dealer.
brakes, starting with removal of the wheels and
continuing through assembly.
Brake Component Inspection
To minimize the possibility of creating airborne brake
lining dust, clean the dust from the brake rotor, brake Air Disc Brakes
caliper, and brake assembly, using an industrial-type 1. Park the vehicle on a level surface, shut down
vacuum cleaner equipped with a high-efficiency filter the engine, and set the parking brake. Chock the
system. Then, using a rag soaked in water and tires. Once the tires are chocked, release the
wrung until nearly dry, remove any remaining dust. parking brake.
Do not use compressed air or dry brushing to clean
the brake assembly. 2. Grip the caliper/carrier assembly by the chamber
and verify that it slides in and out freely. Free
1. Apply the brake and chock the tires to prevent play movement is 0.024 to 0.043 in (0.6 to 1.1
vehicle movement. mm).
2. Check the brake lining wear. On front and rear
axles, replace linings worn to less than 3/16 inch Drum Brakes
(4.8 mm). 1. Park the vehicle on a level surface, shut down
3. Make sure that the brake rotor and linings are the engine, and set the parking brake. Chock the
free of oil and grease. tires. Once the tires are chocked, release the
parking brake.
NOTE: To replace the brake linings, see the ap-
plicable foundation brake section in Group 42 of
the Recreational Vehicle Chassis Workshop WARNING
Manual, or take the vehicle to an authorized Manually adjusting an automatic slack adjuster to
Freightliner dealer. bring the pushrod stroke within legal limits is
likely masking a mechanical problem. Adjustment
42–11 Brake Inspecting is not repairing. Before adjusting an automatic
slack adjuster, troubleshoot the foundation brake
system and inspect it for worn or damaged com-
IMPORTANT: This procedure should be per- ponents. Improperly maintaining the vehicle brak-
formed prior to lubrication of the brake compo- ing system may lead to brake failure, resulting in
nents. property damage, personal injury, or death.
2. With the engine off, and 100 psi (690 kPa) of air
Parking Brake Operational Check tank pressure, have an assistant apply and hold
an 80 to 90 psi (552 to 621 kPa) brake applica-
CAUTION tion.

Perform the following check in a clear safe area. If 3. Check to see if the colored over-stroke band on
the parking brakes fail to hold the vehicle, per- each brake chamber pushrod is exposed.
sonal injury or property damage may result. If a band shows, the stroke is too long. Check
1. With the engine running, and air pressure at cut- the foundation brake components for wear or
out pressure, set the parking brake. damage, and repair as needed. See Group 42 of
the Recreational Vehicle Chassis Workshop

42/10 Recreational Vehicle Chassis Maintenance Manual, July 2018

Brakes 42

Manual for inspection, troubleshooting, and re- 5. Check all of the foundation brake components for
pair procedures. damage, wear, and loose or missing parts. Re-
pair as needed. See Group 42 of the Recre-
4. Measure the applied chamber stroke. See
ational Vehicle Chassis Workshop Manual for
Table 2 for the proper stroke for the type of
inspection, troubleshooting, and repair proce-
chamber being used. If the stroke is too short,
dures.
the brakes may drag or will not fully apply. Check
for improper operation or adjustment of the auto-
matic slack adjuster. See Group 42 of the Rec-
reational Vehicle Chassis Workshop Manual for
inspection, troubleshooting, and repair proce-
dures.

Brake Chamber Stroke Specifications

Chamber
Max Applied Stroke: inch (mm)
Manufacturer Type* Size†
9
1-3/8 (35)
12
16
Standard Stroke 20 1-3/4 (45)
24
30 2 (51)
Gunite
36‡ 2-1/4 (57)
16
20 2 (51)
Long Stroke 24
24
2-1/2 (64)
30
12 1-3/8 (35)
16
Standard Stroke
20 1-3/4 (44)
24
Haldex
2-1/2-Inch Extended Stroke 24 2 (51)
3-Inch Extended Stroke 24 2-1/2 (64)
Standard Stroke 30 2 (51)
Long Stroke 30 2-1/2 (64)

Recreational Vehicle Chassis Maintenance Manual, July 2018 42/11

42 Brakes

Brake Chamber Stroke Specifications

Chamber
Max Applied Stroke: inch (mm)
Manufacturer Type* Size†
9
Less than 1-1/2 (38)
12
Standard Stroke 16
Less than 1-3/4 (44)
Meritor 20
24 Less than 1-7/8 (48)
Long Stroke 24
Less than 2 (51)
Standard Stroke 30
* Long stroke design is indicated by a tag, or embossing, on the brake chamber.
† Specifications are relative to a brake application with 80 to 90 psi (550 to 620 kPa) air pressure in the brake chambers.
‡ If type 36 chamber is used, slack length should be less than 6 inches.

Table 2, Brake Chamber Stroke Specifications

42–12 Meritor Roller Pin contaminated with grease or oil, which can in-
crease stopping distances, causing component
Lubricating damage and serious personal injury.
For Q and P series Meritor brakes, lube the cam an-
WARNING chor and cam roller pins when the brake is disas-
sembled, or every six months, with Meritor specifica-
Remove all grease or oil from the camshaft head, tion grease 0-617-A or 0-617-B. See Fig. 12 for roller
rollers and brake linings. Always replace linings and anchor pin lubrication points.

Brake Chamber Stroke Specifications

Chamber
Max Applied Stroke: inch (mm)
Manufacturer Type* Size†
12 1-3/8 (35)
16
Standard Stroke
20 1-3/4 (44)
24
Haldex
2-1/2-Inch Extended Stroke 24 2 (51)
3-Inch Extended Stroke 24 2-1/2 (64)
Standard Stroke 30 2 (51)
Long Stroke 30 2-1/2 (64)

42/12 Recreational Vehicle Chassis Maintenance Manual, July 2018

Brakes 42

Brake Chamber Stroke Specifications

Table 3, Brake Chamber Stroke Specifications

3. Perform the "In Service Inspection."

In Service Inspection
1. Apply and release the brakes several times while
observing the slack adjuster. The slack adjuster
and brake actuator should move freely, without
binding or interference, and should return to the
1 2 3 full released position. Observe the looseness that
03/02/2004 f430370 exists between the clevis and adapter bushing
and the yoke and link pins and their mating parts
1. Cam Roller Pin Lube Point (Q Series) (clevis, body, link). Replace these parts if loose-
2. Cam Roller Pin Lube Points (Q, Q Plus, and P ness appears excessive. Make certain the brake
Series)
actuator pushrod jam nut is tightened securely.
3. Cam Anchor Pin Lube Points (Q, Q Plus, and P
Series) 2. Inspect the slack adjuster for physical damage,
paying attention to the link, boot, and clevis. If
Fig. 12, Cam and Anchor Roller Pin Lubrication Points
any components are damaged, repair or replace
them as necessary.
42–13 Versajust Slack Adjuster
3. Measure the brake actuator pushrod stroke while
Inspection and making an 80 to 90 psi (552 to 621 kPa) brake
Lubrication application. Actuator pushrod strokes should not
exceed the values shown in Table 4 and
IMPORTANT: Perform the Brake Inspection Table 5. To achieve the correct pressure for this
test, build the system pressure up to a 100 psi
maintenance operation before lubricating the
(690 kPa). Shut down the engine. Fan the
slack adjusters. brakes to attain a 90 to 95 psi (621 to 655 kPa)
1. Visually check for physical damage, such as bro- reading. Make and hold a full brake application
ken air lines and broken or missing parts. while the strokes are checked.
2. Using a quality multipurpose chassis lubricant,
NLGI Grade 2, lubricate the slack adjuster
through the grease fitting until clean lubricant
flows from the grease relief opening in the boot.

Recreational Vehicle Chassis Maintenance Manual, July 2018 42/13

42 Brakes

Actuator Stroke–Standard Stroke Leakage Test

Recommended Maximum Perform the following test after repairing or replacing
Brake Actuator Size
Operating Stroke (Inches)
the DV-2 valve, to ensure that the valve is function-
30 2 ing properly.
24 1-3/4 With the system charged and pressure stabilized in
20 1-3/4 the system, there should be no leaks at the drain
valve exhaust port. A constant slight exhaust of air at
16 1-3/4
the drain valve exhaust port could be caused by ex-
12 1-3/8 cessive leakage in the air brake system.
Table 4, Actuator Stroke–Standard Stroke If the drain valve is leaking excessively, repair or re-
place it. See Section 42.08 of the Recreational Ve-
hicle Chassis Workshop Manual.
Actuator Stroke–Long Stroke
Recommended Maximum
Brake Actuator Size
Operating Stroke (Inches)
30 Long Stroke 2-1/2
24 Long 2
24 Long Stroke 2-1/2
20 Long 2
16 Long 2
Table 5, Actuator Stroke–Long Stroke

42–14 Bendix Automatic Drain

Valve Operating and
Leakage Tests
Operating Test
Perform the following test after repairing or replacing
the DV-2 valve, to ensure that the valve is function-
ing properly.
With the system charged, apply the brakes several
times. Each time the brakes are applied, an exhaust
of air should occur from the exhaust port of the drain
valve. If no air comes out, push the wire stem lo-
cated inside the exhaust port. If no air comes out
after pushing the wire stem, there may be a plugged
filter in the adapter which should be replaced.
If the drain valve does not function properly, repair or
replace it. See Section 42.08 of the Recreational
Vehicle Chassis Workshop Manual.

42/14 Recreational Vehicle Chassis Maintenance Manual, July 2018

Steering 46
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Drag Link Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–01
Hydraulic Reservoir Filter Changing (metal reservoir only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–06
Power Steering Fluid and Filter Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–03
Power Steering Reservoir Fluid Level Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–02
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–00
Steering Driveline Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–04
Steering Gear Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–05

Recreational Vehicle Chassis Maintenance Manual, June 2015

Steering 46

46–00 Safety Precautions leakage could cause loss of power steering assist,
possibly resulting in personal injury and property
damage.
Safety Precautions in this section apply to all
procedures within this group. 3. With the power steering fluid at operating tem-
perature, check the fluid level on the dipstick. If
below the "Add" mark, add enough fluid to bring
DANGER the level up to the "Full" mark on the dipstick.
When working on the vehicle, shut down the en- See Table 1 for approved power steering fluid.
gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place Approved Power Steering Fluid
jack stands under the frame rails to ensure the Fluid Type Approved Fluid*
vehicle cannot drop. Failure to follow these steps Automatic Transmission Fluid Dexron® III
could result in serious personal injury or death.
* Use the same lubricant when assembling parts as is used in the power
steering system.

46–01 Drag Link Lubricating Table 1, Approved Power Steering Fluid

4. Install the dipstick (fill cap) in the power steering
1. Using a clean rag, wipe the dirt from both grease reservoir.
fittings on the drag link.
2. Using a pressure gun, apply multipurpose chas- Rear-Mounted
sis grease at the grease fittings until old grease
is forced out of the socket. 1. Park the vehicle on a level surface, shut down
the engine, and apply the parking brake. Chock
NOTE: Use multipurpose chassis grease NLGI the rear tires.
grade 1 (6% 12-hydroxy lithium stearate grease) 2. Clean around the power steering reservoir cap
or NLGI grade 2 (8% 12-hydroxy lithium stear- with a clean rag, then remove the reservoir cap.
ate grease). The grade 2 chassis grease is pre- See Fig. 1.
ferred.

46–02 Power Steering

Reservoir Fluid Level MAX
Checking
Min
Side-Mounted
1. Park the vehicle on a level surface, shut down
the engine, and apply the parking brake. Chock
the rear tires.
2. Clean around the power steering reservoir dip-
stick (fill cap) with a clean rag, then remove the
dipstick.
04/10/97 f461177

WARNING Fig. 1, Steering System Hydraulic Fluid Reservoir (rear-

mounted)
Fill only with approved clean fluid. Do not mix
fluid types. Any mixture or any unapproved fluid
could lead to seal deterioration and leaks. Fluid

Recreational Vehicle Chassis Maintenance Manual, June 2015 46/1

46 Steering

WARNING
Fill only with approved clean fluid. Do not mix 3
fluid types. Any mixture or any unapproved fluid
could lead to seal deterioration and leaks. Fluid
leakage could cause loss of power steering assist,
possibly resulting in personal injury and property
damage.
4
IMPORTANT: Do not confuse coolant with hy-
draulic fluid. Both are pink in color. 5
3. Fill the reservoir to a level between the MIN and
MAX marks. Use only Dexron III automatic trans-
mission fluid (ATF), or an equivalent. See 2
Table 1 for approved power steering fluid.
4. Replace the reservoir cap.

46–03 Power Steering Fluid

and Filter Changing 1

WARNING 12/16/2013 f462248

1. Power Steering Fluid Reservoir

Fill only with approved clean fluid. Failure to use 2. Gasket
the proper fluid could cause seal deterioration and 3. Reservoir Cover
leaks. Fluid leaks could eventually cause loss of 4. Dipstick
power steering assist. This could lead to an acci- 5. Filter
dent resulting in personal injury or property dam-
age. Wear eye protection when changing the fluid Fig. 2, 1.6- and 2-Quart Reservoir
and filter. NOTE: Always replace the power steering reser-
1. Park the vehicle on a level surface, shut down voir filter when changing the fluid.
the engine, and set the parking brake. Chock the
6. Remove the power steering filter. It may be nec-
rear tires.
essary to wiggle the filter to remove it from its
2. Place a drain pan under the power steering res- base. Do not use pliers to aid in removal of the
ervoir. filter; pliers could cause metal chips to enter the
3. Remove the steering gear-to-reservoir return steering system.
hose at the reservoir and position it to drain into 7. Clean the inside of the reservoir using a lint-free
the pan. cloth.
4. Plug the return line fitting on the reservoir. 8. Raise the front of the vehicle with a floor jack
5. Remove the reservoir cover. and support it with jack stands.

For the 1.6- and 2-quart reservoir, unscrew and 9. Place the disconnected end of the steering gear-
remove the reservoir cover. See Fig. 2. to-reservoir hose in a drain pan.

For the 4-quart reservoir, loosen and then re- IMPORTANT: Do not start the engine while
move the retaining ring, filter top plate, and gas- draining the system.
ket. See Fig. 3. 10. Have someone turn the steering wheel to full
lock left and right several times until clean power

46/2 Recreational Vehicle Chassis Maintenance Manual, June 2015

Steering 46

For the 4-quart reservoir, install the gasket, filter

top plate, and retaining ring, then hand-tighten
3 the retaining ring.
15. Fill the power steering reservoir with Dexron III.
4
Fill the 1.6- and 2-quart reservoir to the MAX
COLD mark.
5
Fill the 4-quart reservoir to the mark between the
6 MIN COLD and MAX HOT marks.
IMPORTANT: Do not allow the reservoir to
2 empty and pull air into the power steering sys-
tem.
16. Start the engine and let it idle for about 15 sec-
onds, then check the reservoir and add fluid as
needed.
Since the power steering lines were drained, this
1 will need to be done several times before the
reservoir will remain full.
17. Start the engine and operate it at idle. Turn the
steering wheel to full lock left and right to adjust
the fluid level and remove any air from the power
steering pump and gear. Recheck the fluid level.
Add fluid as needed. The system is properly bled
when the steering pump does not labor when
08/23/2013 f462246 turning the wheel.
1. Power Steering Fluid Reservoir 18. Remove the jackstands and lower the vehicle.
2. Reservoir Fill Cap
3. Retaining Ring
4. Filter Top Plate 46–04 Steering Driveline
5.
6.
Gasket
Filter
Lubricating
Fig. 3, 4-Quart Reservoir Wipe the grease fittings clean. Using a pressure gun,
apply a lithium-based grease (NLGI grade 2) spar-
steering fluid flows from the hose into the drain ingly to the universal joints and slip-joint splines.
pan. Add fluid to the reservoir as needed.
11. Once clean fluid comes out of the hose, remove
the plug from the reservoir and reconnect the
46–05 Steering Gear
steering gear-to-reservoir hose to the reservoir. Lubricating
12. Install a new power steering filter in the reservoir. 1. Wipe off debris from the grease fitting.
13. Inspect the reservoir cover and gasket for any 2. Using a hand-type grease gun, apply multipur-
damage. Replace the reservoir cover or gasket if pose chassis grease until the grease starts com-
needed. ing out of the sector shaft dirt and water seal.
14. Install the reservoir cover. Figure 4 shows the location of the sector shaft
grease fitting.
For the 1.6- and 2-quart reservoir, install the
cover and hand-tighten.

Recreational Vehicle Chassis Maintenance Manual, June 2015 46/3

46 Steering

10. Start the engine. Run the engine at half-throttle

until the fans engage (loud chirping sound). Shut
down the engine.
11. The fan circuit is now purged. Top off the reser-
voir fluid and install the reservoir lid.

04/13/93 f460515a

1. Sector Shaft Grease Fitting

Fig. 4, Sector Shaft Lubricating

46–06 Hydraulic Reservoir

Filter Changing (metal
reservoir only)
NOTE: On XC chassis vehicles with a side-
mounted radiator, the hydraulic reservoir sup-
plies both the steering and the fan circuits.
1. Drain the entire steering and fan hydraulic sys-
tems.
2. Remove the reservoir lid and remove the nut that
secures the filter.
3. Remove the old filter and install the new filter.
4. Install the filter nut and tighten it securely.
5. Fill the reservoir with Dexron III.
6. Start the engine, run it for five seconds, then
shut down the engine.
7. Fill the reservoir with Dexron III.
8. Start the engine. Turn the steering wheel lock-to-
lock several times until the steering wheel turns
easily. Shut down the engine.
9. Fill the reservoir with Dexron III.
NOTE: The steering circuit is now purged. Fol-
low the remaining steps to purge the fan circuit.

46/4 Recreational Vehicle Chassis Maintenance Manual, June 2015

Fuel 47
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Fuel Tank Mounts and Fuel Line Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–01
Fuel/Water Separator Element Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–02
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–00

Recreational Vehicle Chassis Maintenance Manual, April 2018

Fuel 47

47–00 Safety Precautions 47–02 Fuel/Water Separator

Safety Precautions in this section apply to all
Element Replacing
procedures within this group.
Alliance
DANGER The only maintenance necessary on an Alliance
fuel/water separator is to replace the filter element.
When working on the vehicle, shut down the en-
gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place WARNING
jack stands under the frame rails to ensure the Diesel fuel is flammable and can ignite if exposed
vehicle cannot drop. Failure to follow these steps to an open flame, intense heat, or other ignition
could result in serious personal injury or death. source. Do not drain fuel near, or expose fuel
vapor to open flame or intense heat. Exposure to
47–01 Fuel Tank Mounts and open flame or intense heat could start a fire, pos-
sibly resulting in personal injury or property dam-
Fuel Line Checking age. When working on a fuel system, have a fire
extinguisher within easy reach.
WARNING 1. Drain off some fuel by loosening the vent plug
and opening the drain valve. See Fig. 1.
Inspect the components as described below. Fail- 2. Disconnect the water sensor and heater connec-
ure to perform these inspections could result in tions if equipped.
the failure of the fuel tank mounting assembly and
loss of vehicle control, possibly causing personal 3. Remove the element and bowl together, by turn-
injury or death, or property damage. ing counterclockwise.
1. Chock the tires. Working at the front of the ve- 4. Remove the bowl from the element and clean
hicle or at the rear of the vehicle, raise the ve- the O-ring seating surface.
hicle so that the tires just clear the ground and 5. Apply a coating of clean fuel or motor oil to the
so that the suspension is fully extended. Place new O-ring and element seal.
safety stands under the vehicle frame.
6. Spin the bowl onto the new element, then spin
2. Check the T-bolts that attach the fuel tank them both onto the filter head, snugly, by hand
mounting straps to the mounting brackets. Check only.
to see that the nuts are tight.
IMPORTANT: Do not use tools to tighten the
3. Inspect the fuel tank straps for damage or wear.
bowl and element.
Replace them if necessary.
7. Connect the water sensor and heater connectors
4. Inspect the fuel tank for leaks or damage. Re-
if equipped.
place the tank if necessary.
8. If equipped with a primer pump, prime the
IMPORTANT: Do not attempt to repair a dam- fuel/water separator.
aged fuel tank; always replace a damaged fuel
tank. 8.1 Loosen the vent plug. Then operate the
primer pump until the fuel purges at the
5. Inspect the fuel lines for damage or wear. vent plug.
6. Remove the safety stands and lower the vehicle. 8.2 Close the vent plug.
Remove the chocks from the tires.
9. Start the engine and check for fuel leaks.
10. Shut down the engine and correct any fuel leaks.

Recreational Vehicle Chassis Maintenance Manual, April 2018 47/1

47 Fuel

2 There is no significant restriction to fuel flow until the

element is completely clogged.
1 3 1. Shut down the engine, apply the parking brake,
and chock the tires.
2. Check the fuel level in the fuel filter. Replace the
4
fuel/water separator element only when the filter
element is completely covered. If the fuel level
has reached the top of the filter element, follow
the procedure below to replace the element.
11
3. Put a clean receptacle under the fuel/water sepa-
rator and attach a piece of hose to the drain
valve, to direct fuel into the receptacle.
5
The drain valve has a 1/2-inch (12.7-mm) pipe;
10 use a hose with a 1/2-inch pipe thread to fit cor-
rectly.
9 6 4. Remove the vent cap, shown in Fig. 2, Item 10,
and open the drain valve, shown in Fig. 2, Item
7 1, to drain the fuel completely, then close the
drain valve.
8
5. Using a DAVCO Collar Wrench, shown in Fig. 3,
06/25/97 f470147 remove the clear cover and collar.
1. Mounting Head 7. Water Sensor Probe
2. Fuel Primer Pump 8. Heater Connector NOTE: Broken vent cap and collar warranty
3. Vent Plug 9. Drain Plug claims will not be accepted if any tool other than
4. Bowl O-Ring 10. Sight Bowl a DAVCO Collar Wrench is used for removal.
5. Bowl Gasket 11. Filter Element During installation, the vent cap is to be hand-
6. Bowl Probe Plug
tightened only, not tightened with a wrench.
Fig. 1, Alliance Fuel/Water Separator Use part number 482017 on Fuel Pro 482 units;
part number 380134 on Fuel Pro 382 units.
DAVCO Fuel Pro® 382 and 482 6. Remove the filter, cover O-ring, and vent cap
O-ring. Dispose of them in an environmentally
WARNING acceptable manner. See Fig. 2 or Fig. 4.
7. Clean all threads and sealing surfaces very thor-
Fluid circulated through the fuel/water separator
oughly. Even a small amount of dirt will prevent
to heat the fuel may be diesel fuel returned from
the fuel/water separator from sealing, and an air
the engine, or engine coolant. Drain the fuel/water
leak may result.
separator only when the engine and fluids have
cooled. Draining it when the engine is hot could 8. On Fuel Pro 382 units, install the grommet on
cause severe personal injury due to scalding. the bottom of the new filter.
If returning fuel is released into the atmosphere, 9. Install the new filter and grommet assembly and
its vapors can ignite in the presence of any igni- cover O-ring on the housing.
tion source. Do not expose the fuel to, or work 10. Install the clear cover and the collar. Simultane-
with the fuel system near, open flame or intense ously apply downward pressure to the top of the
heat. To do so could cause fire, possibly resulting clear cover until it is seated on the body of the
in serious personal injury or property damage. lower housing and hand tighten the collar until it
The filter element should be changed only when the no longer spins freely. Using the collar wrench,
fuel level has reached the top of the filter element. tighten the cover 18 lbf·ft (24 N·m). This is
equivalent to rotating the collar clockwise two or

47/2 Recreational Vehicle Chassis Maintenance Manual, April 2018

Fuel 47

VENT CAP
FOR REMOVAL OF TOP COLLAR ONLY

02/16/2009 f470277
8
Fig. 3, DAVCO Collar Wrench

three additional ribs, depending on the specific

filter model.
11. Prime the system.
7
11.1 Ensure that the drain valve is closed.
11.2 Fill the housing to the top of the filter ele-
ment with clean diesel fuel.
11.3 Install and hand-tighten the vent cap
O-ring and vent cap.
6
11.4 Start the engine. When the lubricating oil
reaches its normal operating pressure,
12 increase engine speed to high idle for
one to two minutes to purge air from the
system.
5
11.5 While the engine is running, and after the
air is purged from the system, loosen the
vent cap until the fuel level falls to about
4 one inch (2.5 cm) above the collar, then
hand-tighten the vent cap.
13
11.6 Check for leaks and shut down the
3 engine.
14
2 Detroit
The only maintenance necessary on an Detroit
1 fuel/water separator is to replace the filter element.
12/13/2010 f470531a
See Fig. 5.
1. Drain Valve 8. Clear Cover
2. Bottom Plate 9. Vent Cap O-Ring WARNING
Assembly 10. Vent Cap
3. Bottom Plate O-Ring 11. Collar Fluid circulated through the fuel/water separator
4. Lower Housing 12. Grommet to heat the fuel may be diesel fuel returned from
5. Cover O-Ring 13. Inlet Port/Check Valve the engine, or engine coolant. Drain the fuel/water
6. Filter Element 14. Heat Exchanger separator only when the engine and fluids have
7. Spring cooled. Draining it when the engine is hot could
Fig. 2, DAVCO Fuel Pro 382 cause severe personal injury due to scalding.

Recreational Vehicle Chassis Maintenance Manual, April 2018 47/3

47 Fuel

9 1

6 2

06/09/2016 f470689
1. Mounting Head 2. Sight Bowl

4 Fig. 5, Detroit Fuel/Water Separator

If returning fuel is released into the atmosphere,

its vapors can ignite in the presence of any igni-
11
tion source. Do not expose the fuel to, or work
3 with the fuel system near, open flame or intense
12 heat. To do so could cause fire, possibly resulting
in serious personal injury or property damage.
2
1. Drain off some fuel by loosening the vent plug
and opening the drain valve.
2. Disconnect the water sensor and heater connec-
tions if equipped.
3. Remove the bowl by turning counterclockwise.
4. Remove the element, bowl O-ring, and element
1 13
o-ring. Dispose of them in an environmentally
05/05/2009 f470530 acceptable manner.
1. Inlet Port/Check Valve 8. Vent Cap O-Ring 5. Thoroughly clean all of the threads and sealing
2. Lower Housing 9. Vent Cap surfaces. Even a small amount of dirt will prevent
3. Bypass Valve 10. Lower Housing Collar
the fuel/water separator from sealing, and an air
4. Filter Element 11. 120VAC Pre-Heater
5. Spring 12. 12VDC Pre-Heater leak may result.
6. Clear Cover O-Ring 13. Drain Valve 6. Apply a coating of clean fuel or motor oil to the
7. Clear Cover new O-ring and to the new element o-ring.
Fig. 4, DAVCO Fuel Pro 482 7. Insert the new element into the upper housing.

47/4 Recreational Vehicle Chassis Maintenance Manual, April 2018

Fuel 47

IMPORTANT: Do not use tools to tighten the

bowl and element.
8. Spin the bowl onto the onto the upper housing
by hand only.
9. Connect the water sensor and heater connectors
if equipped.
10. If equipped with a primer pump, prime the
fuel/water separator as follows.
10.1 Loosen the vent plug. Then operate the
primer pump until the fuel purges at the
vent plug.
10.2 Close the vent plug.
11. Start the engine and check for fuel leaks.
12. Shut down the engine and correct any fuel leaks.

Recreational Vehicle Chassis Maintenance Manual, April 2018 47/5

Exhaust 49
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Exhaust System Inspecting (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–01
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–00

Recreational Vehicle Chassis Maintenance Manual, November 2015

Exhaust 49

49–00 Safety Precautions • Aftertreatment Device (ATD)—a device that re-

moves pollutants from exhaust gas after the gas
leaves the combustion chamber.
Safety Precautions in this section apply to all
procedures within this group. • BlueTec®—Daimler’s proprietary SCR technol-
ogy.
DANGER • Diesel Oxidation Catalyst (DOC)—a flow-
through device that enhances the oxidation of
When working on the vehicle, shut down the en- hydrocarbons in the ATD.
gine, set the parking brake, and chock the tires.
• Diesel Particulate Filter (DPF)—a component in
Before working under the vehicle, always place
the ATD that traps particulate matter from the
jack stands under the frame rails to ensure the
exhaust gas.
vehicle cannot drop. Failure to follow these steps
could result in serious personal injury or death. • Diesel Exhaust Fluid (DEF)—the chemical agent
that reacts with the exhaust gases in the SCR
to reduce NOx.
49–01 Exhaust System • DEF Pump—filters and supplies DEF to the
Inspecting (Noise DEF metering unit.
Emission Control) • DEF Tank—holds DEF and regulates its tem-
perature.
The exhaust system must be free of leaks, binding,
• DEF Metering Unit—mixes DEF with com-
grounding, and excessive vibrations. In addition to
pressed air, and meters this mixture into the
inspecting the exhaust system at the scheduled
exhaust flow via an injection nozzle.
maintenance interval, inspect the exhaust system if
the noise level of the vehicle has increased. Replace • SCR Catalyst—the housing containing a treated
parts that show leakage, wear, or damage, with ceramic flow-through block where the DEF and
genuine Freightliner parts. exhaust gases undergo selective catalytic re-
duction.
These conditions are usually caused by loose, bro-
ken, or misaligned clamps, brackets, or pipes. If any • Selective Catalytic Reduction (SCR)—a process
of these conditions exist, check the exhaust system used to reduce NOx emissions.
components and alignment. Align or replace as nec-
essary. For alignment or adjustment instructions, see Inspection
Group 49 of the Recreational Vehicle Chassis Work-
shop Manual, or take the vehicle to an authorized IMPORTANT: The Environmental Protection
Freightliner dealer. Agency’s 2010 regulations mandate lowered
exhaust emissions, thus requiring exhaust sys-
EPA10 and Newer Exhaust tem components that reduce emissions. In par-
ticular the aftertreatment device (ATD), which is
System part of the aftertreatment system (ATS), requires
Definitions of Aftertreatment special attention during regularly scheduled
maintenance inspections. See Fig. 1 for Cum-
System (ATS) Terms mins ATD sensor locations. If any discrepancies
Refer to the following list of definitions of ATS terms are discovered, refer to the engine manufactur-
and components. er’s service literature for repair instructions.
• Aftertreatment System (ATS)—the entire ex- 1. Check for leakage at the clamp that attaches the
haust system from the turbocharger to the tail exhaust pipe to the turbocharger exhaust outlet.
pipe, including the Selective Catalytic Reduction If leakage exists, tighten the nut on the clamp to
(SCR) components. the required torque. If leakage persists, install a
new clamp.

Recreational Vehicle Chassis Maintenance Manual, November 2015 49/1

49 Exhaust

4
6. Check all sensors attached to the ATD for leaks
5 or damaged wires. No leaks are allowed.
7. Check the DPF exterior surface for dents or
other damage. A dent over 3 inches (76 mm) in
3 diameter and 1/4-inch (6-mm) deep could cause
internal damage to the DPF, causing it to mal-
function.
6 8. Check the SCR catalyst for dents and other
damage.
9. Check for heat discoloration on the surface of
the ATD. Heat discoloration may indicate internal
damage; especially around the DPF.
NOTE: Diesel exhaust fluid creeps, causing
white crystals to form around the line fittings.
2
The presence of crystals does not mean the
system has a leak. Replacing fittings or trouble-
1
shooting components is not necessary unless
7 there is a system failure or a fault code.
10/20/2009 f490386
10. Check the DEF tank, pump, metering unit, and
lines for leaks. See Group 49 of the Recre-
1. Exhaust Outlet ational Vehicle Chassis Workshop Manual for
2. SCR Outlet NOx Sensor repair procedures.
3. DPF Outlet Pressure Sensor
4. DPF Intake Pressure Sensor 11. Check any wires, lines, or hoses within 4 inches
5. DPF Inlet Temperature Sensor (10 cm) of the exhaust system for heat damage.
6. SCR Inlet Temperature Sensor Repair or reroute as needed.
7. SCR Outlet Temperature Sensor
Diesel Exhaust Fluid (DEF) Filter
Fig. 1, Cummins ATD Sensor Locations
Replacement
2. Check the exhaust pipe, bellows, and each ex-
The Environmental Protection Agency’s 2010 regula-
haust seal clamp for leakage, wear, cracks, or
tions require lower nitrogen oxide (NOx) exhaust
damage. Replace damaged components as
emissions. Selective catalytic reduction (SCR) uses
needed. If leakage exists at a clamp, tighten the
diesel exhaust fluid (DEF) to lower NOx emissions in
nuts to the required torque. If leakage persists,
the vehicle exhaust. A filter in the DEF pump pre-
install a new exhaust seal clamp. Do not reuse
vents clogging of the DEF metering unit injection
seal clamps. Once a seal clamp is loosened or
nozzle.
removed, it must be replaced.
See the engine manufacturer’s maintenance manual
3. If present, check the condition of the insulation
for DEF filter replacement instructions and mainte-
material around the exhaust pipe between the
nance intervals.
turbocharger and the ATD.
4. Check the ATD mounting bands for tightness. EPA07 Exhaust System
Tighten to 30 lbf·ft (41 N·m) if needed. Do not
overtighten. Definitions of ATS Terms
5. Check for leaks around the clamps that attach Refer to the following list of definitions of ATS terms
the ATD in the ATS, and around the clamps that and components.
retain the DPF in the ATD. No leaks are allowed
anywhere in the system. • Aftertreatment System (ATS) — the entire ex-
haust system from the turbocharger to the tail
pipe.

49/2 Recreational Vehicle Chassis Maintenance Manual, November 2015

Exhaust 49

• Aftertreatment Device (ATD)—a muffler-like can- retain the DPF in the ATD. No leaks are allowed
ister that houses a DPF and sensors. anywhere in the system.
• Diesel Particulate Filter (DPF)—a filter that col- 6. Check all sensors attached to the ATD for leaks
lects and holds particulate matter (soot and or damaged wires. No leaks are allowed.
ash). 7. Check the DPF exterior surface for dents or
• Diesel Oxidation Catalyst (DOC)—oxidizes hy- other damage. See Fig. 2, Item A. A dent over 3
drocarbons and reduces NOx. inches (76 mm) in diameter and 1/4-inch (6-mm)
deep could cause internal damage to the DPF,
• Sensors—detect temperatures and pressure
causing it to malfunction.
within the ATS.
8. Check for heat discoloration on the surface of
• Diffuser—a device, used as a deflector, for dis-
the ATD. Heat discoloration may indicate internal
tributing, mixing, and reducing the velocity of air
damage; especially around the DPF.
flow.
9. Check any wires, lines, or hoses within 4 inches
Inspection (10 cm) of the exhaust system for heat damage.
Repair or reroute as needed.
IMPORTANT: The Environmental Protection
Agency’s 2007 regulations require lower ex-
haust emissions, thus requiring new exhaust
system components. See Fig. 2. In particular
the aftertreatment device (ATD), which is part of
the aftertreatment system (ATS), requires spe-
cial attention during regularly scheduled mainte-
nance inspections. If any discrepancies are dis-
covered, refer to the engine manufacturer’s
service literature for repair instructions.
1. Check for leakage at the clamp that attaches the
exhaust pipe to the turbocharger exhaust outlet.
If leakage exists, tighten the nut on the clamp to
the required torque. If leakage persists, install a
new clamp.
2. Check the exhaust pipe, bellows, and each ex-
haust seal clamp for leakage, wear, cracks, or
damage. Replace damaged components as
needed. If leakage exists at a clamp, tighten the
nuts to the required torque. If leakage persists,
install a new exhaust seal clamp. Do not reuse
seal clamps. Once a seal clamp is loosened or
removed, it must be replaced.
3. If present, check the condition of the insulation
material around the exhaust pipe between the
turbocharger and the ATD, as well as the ex-
haust wrap from the ATD to the diffuser.
4. Check the ATD mounting bands for tightness.
Tighten to 30 lbf·ft (41 N·m) if needed. Do not
overtighten.
5. Check for leaks around the clamps that attach
the ATD in the ATS, and around the clamps that

Recreational Vehicle Chassis Maintenance Manual, November 2015 49/3

49 Exhaust

3
2 4
1 B
5

4
C

9
A

6
7
11/2/2006 f490284

A. Inspect this area of the canister for dents. C. DPF Area

B. DOC Area
1. Inlet Temperature Sensor 6. Exhaust Outlet to Diffuser
2. Marmon Fitting at Inlet from Turbocharger 7. Outlet Temperature Sensor
3. Sensor Housing 8. DPF Outlet Pressure Sensor
4. DPF V-Band Mounting Clamps 9. DPF Intake Pressure Sensor
5. Inlet Temperature Sensor

Fig. 2, Cummins Aftertreatment Device

49/4 Recreational Vehicle Chassis Maintenance Manual, November 2015

Electrical, Instruments, and Controls 54
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Battery Voltage Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54–02
Ground Cables Checking and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54–01

Recreational Vehicle Chassis Maintenance Manual, September 2007

Electrical, Instruments, and Controls 54

54–01 Ground Cables

Checking and Cleaning
Check that the ground cables are clean, undamaged,
and tight. If needed, disconnect them, clean the mat-
ing surfaces with a soda solution, then connect them
securely. Spray the ground cable connections with
dielectric red enamel.

54–02 Battery Voltage

Checking
Check the battery open circuit voltage using an accu-
rate voltmeter. If the voltmeter registers 12.5V or
below, fully charge the battery to 12.65V. A fully
charged battery will have a voltage of 12.65V with
the charger disconnected.

Recreational Vehicle Chassis Maintenance Manual, September 2007 54/1

Heater and Air Conditioner 83
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Air Conditioner Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–01
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–00

Recreational Vehicle Chassis Maintenance Manual, June 2015

Heater and Air Conditioner 83

83–00 Safety Precautions 4. Check the overall condition of the air conditioning
hoses. Look for cracks, cuts, and abrasions on
the hoses. Replace damaged hoses; see Group
Safety Precautions in this section apply to all 83 of the Recreational Vehicle Chassis Work-
procedures within this group. shop Manual for replacement instructions, or
take the vehicle to an authorized Freightliner
DANGER dealer. Also, visually check for loose fittings on
all air conditioning components. Do not over-
When working on the vehicle, shut down the en- tighten the fittings.
gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place 5. Check for a buildup of road debris on the con-
jack stands under the frame rails to ensure the denser fins. Using air pressure and a whisk
vehicle cannot drop. Failure to follow these steps broom or a soapy spray of water, carefully clean
could result in serious personal injury or death. off the condenser. Be careful not to bend the
fins.

83–01 Air Conditioner

Inspecting
WARNING
Wear eye protection, gloves, and protective cloth-
ing when working on the air conditioning system.
Leaking refrigerant from a damaged hose or line
could cause blindness or serious skin burns.
1. Park the vehicle on a level surface, shutdown the
engine, apply the parking brake, and chock the
tires.

CAUTION
To avoid the possibility of burns, make certain
that the engine and air conditioner components
are not hot.
2. Check the appearance of the air conditioner
compressor pulley assembly. If the friction sur-
face of the pulley shows signs of excessive
grooving due to belt slippage, replace both the
pulley and the drive plate. Visually inspect the
refrigerant compressor drive belt for damage,
and check that the belt is set at the proper ten-
sion. Also check the tightness of the compressor
mounting fasteners. For instructions and torque
values and for removal and installation proce-
dures, see Group 83 of the Recreational Vehicle
Chassis Workshop Manual, or take the vehicle to
an authorized Freightliner dealer.
3. Inspect the compressor clutch coil wire. Ensure
that the connector is not damaged or loose. Re-
place the wire if it is damaged.

Recreational Vehicle Chassis Maintenance Manual, June 2015 83/1

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